1998 OPEL FRONTERA wiring

6A–2
ENGINE MECHANICAL
Piston and Connecting Rod 6A–77. . . . . . . . . . . . . . .
Piston, Connecting Rod and Associate
Parts 6A–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 6A–77. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–78. . . . . . . . . . . . . . . . . .
Reassembly 6A–82. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block 6A–85. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block and Associated Parts 6A–85. . . . .
Disassembly 6A–85. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–86. . . . . . . . . . . . . . . . . .
Reassembly 6A–87. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specification 6A–90. . . . . . . . . . . . . .
Special Tool 6A–96. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

6A–18
ENGINE MECHANICAL
Cylinder Head Cover LH
Removal
1. Disconnect battery ground cable.
2. Drain engine coolant from faucet bottom of radiator.
3. Remove engine cover from the dowels on the
common chamber.
F06RW018
4. Remove air cleaner duct assembly (3) and air cleaner
element (4).
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.5. Disconnect following wiring connectors and bonding
cable:
Manifold Absolute Pressure (MAP) sensor
Vacuum Switching Valve (VSV) for Induction Air
Control Valve (IACV) actuator
Ignition coils for left bank
Fuel injectors for left bank
Idle air control (IAC) valve
Throttle position sensor (TPS)
Bonding cable
Others as necessitated
6. Disconnect following vacuum hoses:
Brake master VAC
Canister
VSV for IACV actuator
Duty solenoid valve
PCV
7. Disconnect radiator upper and lower hoses
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019

6A–20
ENGINE MECHANICAL
5. Install auto tensioner assembly and tighten the fixing
bolts to the specified torque.
Torque :
Shorter Bolt : 20 Nꞏm (2.0 Kgꞏm/14 lb ft)
Longer Bolt : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
6. Install idle pulley and bracket assembly and tighten
the fixing bolt to the specified torque.
Torque : 52 Nꞏm (5.3 Kgꞏm/38 lb ft)
7. Install fan pulley and bracket assembly and tighten
the fixing bolts and nut to the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
8. Install power steering oil pump pulley and tighten the
fixing bolt to the specified torque.
Torque : 78 Nꞏm (8.0 Kgꞏm/58 lb ft)
9. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
10. Install cooling fan and clutch assembly and tighten
the fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/87 lb in)
11. Install upper fan guide and clip both side and tighten
the fixing bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
12. Install engine harness and tighten the fixing bolts of
the retaining clip and bracket to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
13. Connect radiator upper and lower hoses and clip
them securely.
14. Connect vacuum hoses of those which were
disconnected in the removal step.
15. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
16. Install air cleaner element and air cleaner duct
assembly, and clip the both end securely.
17. Connect MAF sensor connector, IAT sensor
connector and PCV hose.
18. Install engine cover mating with the dowels.

6A–21
ENGINE MECHANICAL
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove battery from the vehicle.
3. Drain engine coolant from faucet bottom of radiator.
4. Remove engine cover from the dowels on the
common chamber.
F06RW018
5. Remove air cleaner duct assembly (3) and air cleaner
element (4).
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.
6. Disconnect following wiring connectors and bonding
cable:
Exhaust Gas Recirculation (EGR) valve
Fuel injectors for right bank
Ignition coils for right bank
Bonding cable
Othres as necessitated
7. Disconnect radiator upper and lower hoses.
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
(6) Power Steering Oil Pump
(7) Drive Belt
(8) Air Conditioner Compressor
12. Remove fan pulley and bracket assembly.
13. Remove idle pulley assembly.
14. Remove auto tensioner assembly.
15. Remove crankshaft pulley using 5–8840–0133–0
crankshaft holder.

6A–23
ENGINE MECHANICAL
6. Install idle pulley assembly and tighten the fixing bolt
to the specified torque.
Torque : 52 Nꞏm (5.3 Kgꞏm/38.4 lb ft)
7. Install fan pulley and bracket assembly and tighten
the fixing bolts and nut to the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16.2 lb ft)
8. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
9. Install cooling fan clutch assembly and tighten the
fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in)
10. Install upper fan guide and clip both side and tighten
the fixing bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35.4 lb in)
11. Install engine harness and tighten the fixing bolts of
the retaining clip and brackets to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35.4 lb in)
12. Connect radiator upper and lower hoses and clip
them securely.
13. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
14. Install air cleaner element and air cleaner duct
assembly, and the clip both end securely.
15. Connect MAF sensor connector, IAT sensor
connector and PCV hose.
16. Install engine cover mating with the dowels.

ENGINE COOLING6B–1
ENGINE
ENGINE COOLING
CONTENTS
Service Precaution 6B–1. . . . . . . . . . . . . . . . . . . . . .
General Description 6B–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Refilling Cooling System 6B–6. . . . .
Water Pump 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump and Associated Parts 6B–7. . . . . . .
Removal 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat and Associated Parts 6B–8. . . . . . . .
Removal 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator 6B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator and Associated Parts 6B–9. . . . . . . . . .
Removal 6B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Belt and Cooling Fan 6B–12. . . . . . . . . . . . . . .
Drive Belt and Associated Parts 6B–12. . . . . . . . .
Inspection 6B–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6B–13. . . . . . . . . . . . .
Special Tool 6B–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

6C–1
ENGINE FUEL
ENGINE
ENGINE FUEL
CONTENTS
Service Precaution 6C–1. . . . . . . . . . . . . . . . . . . . . .
General Description 6C–2. . . . . . . . . . . . . . . . . . . . .
Fuel Metering 6C–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 6C–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter and Associated Parts 6C–4. . . . . . . . .
Removal 6C–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
In–Tank Fuel Filter 6C–5. . . . . . . . . . . . . . . . . . . . .
Fuel Pump Flow Test 6C–5. . . . . . . . . . . . . . . . . . .
Fuel Pump 6C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump and Associated Parts 6C–6. . . . . . . .
Removal 6C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay 6C–7. . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C–7. . . . . . . . . . . . . . . . . . . . .
Fuel Tank 6C–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank and Associated Parts 6C–7. . . . . . . . .
Removal 6C–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tube / Quick – Connect Fittings 6C–8. . . . . . .
Precautions 6C–8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions During Work 6C–8. . . . . . . . . . . . . . . . . .
Removal 6C–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reuse of Quick–Connector 6C–10. . . . . . . . . . . . . . .
Assembling Advice 6C–10. . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit 6C–11. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit and Associated Parts 6C–11. . .
Removal 6C–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filler Cap 6C–12. . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C–12. . . . . . . . . . . . . . . . . . . . .
Inspection 6C–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6C–12. . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

6C–7
ENGINE FUEL
Fuel Pump Relay
General Description
In order to control the FP operation, the FP relay is
provided. When the starter switch is turned to “ON”
position, the FP relay operates the FP for 2 seconds.When it is turned to “START” position, the Power Train
Control Module (PCM) receives the reference pulse from
the Ignition Control Module and it operates the relay,
again causing the FP to feed fuel.
Fuel Tank
Fuel Tank and Associated Parts
035RW048
Legend
(1) Fender Liner
(2) Fuel Filler Hose and Air Breather Hose and
Evapo Hose
(3) Undercover(4) Fuel Tank Wiring Connector
(5) Evapo Fuel Hose
(6) Fuel Feed Tube and Fuel Return
Tube/Quick–Connect Fittings
(7) Fuel Tank
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission”.
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.3. Drain fuel.
Tighten drain plug to the specified torque after
draining fuel.
Torque: 20 Nꞏm (2.0 Kgꞏm/14 lb ft) — M8
4. Remove fender liner (1) of wheel well on rear right
side.
5. Fuel filler hose, air breather hose and evapo hose (2).
6. Remove undercover fixing bolts on both sides and
remove under cover(3).