1998 OPEL FRONTERA fuel filter

D08RW737
BRAKE EHCU:ELECTRONIC HYDRAULIC CONTROL UNIT
SEDIMENTER 4WD
BRAKE
FLUID
SWPARKING
BRAKE
SW
18
19
4WD
CONTROL
UNIT(19)
FRT AXLE
SW(2)4WD
SW(1)0.5
LG
0.5
LG 0.5
LG 0.5
LGI-9
H-2723
7
2 0.5
V
0.3
V0.5
B/P
0.85
B/P
0.5
B0.5
B/P0.5
B/P I-9
H-9
H-674
1
8 9
213
1
FENDER-RH0.5
B/PI-9
H-16
C-15
C-39 C-15FUEL
FILTER
SW
0.5
B1
2
FENDER-L HC-16 C-67
VACUUM
SW
1
C-68H-26
B-27
METER

D08RW914
H
SEAT
BELT
SW
BODY-LH
B-18
BODY-CTRBODY-RH
B-2
2
11 0.3
L
0.5
L
2.0
B 2.0
B 2.0
B 0.5
BI-9
B-24 H-25
1
B-24
SEAT
BELT
B-262
BRAKE EHCU:ELECTRONIC HYDRAULIC CONTROL UNIT
SEDIMENTER 4WD
BRAKE
FLUID
SWPARKING
BRAKE
SW
18
22
4WD
CONTROL
UNIT(19)
FRT AXLE
SW(2)4WD
SW(1) SDM
(20)0.5
LG
0.5
LG 0.5
LG 0.85
LGI-9
H-2523
20
2 0.5
V
0.3
V0.5
B/P
0.85
B/P
0.5
B0.5
B/P0.5
B/P I-9
H-9
H-674
1
3 17
215
1
FENDER-LH0.5
B/PI-9
H-9
C-15
C-16 C-15FUEL
FILTER
SW
0.5
B1
2
FENDER-L HC-16 C-67
VACUUM
SW
1
C-68H-25
B-27
METER

8J–4EXTERIOR/INTERIOR TRIM
Consoles
Consoles and Associated Parts
This illustration is based on RHD
745RW009
Legend
(1) Shift Knob (M/T) / Transfer Knob (A/T)
(2) Assist Grip
(3) Fuel Filler Lid Opener(4) Center Console Assembly
(5) Front Seat Assembly (RH)
(6) Front Console Assembly
Removal
1. Disconnect the battery ground cable.
2. Remove the shift knob (M/T) / transfer knob (A/T).
3. Remove the front console assembly.
Remove four fixing screws and disconnect the
switch connectors.
4. Remove the front seat assembly(RH).
Refer to the Front Seat Assembly removal steps in
Seats section.
5. Remove the assist grip.
Remove three bolts.
6. Remove the fuel filler lid opener.
Remove the fuel filter lid opener(1) and disconnect
the cable(2).
686RW007

6A–3
ENGINE MECHANICAL
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick–up unit.
The 12–volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die–cast casting
for 75
V–type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent–roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V–type design. The ports are cross–flow
type.
Va l v e Tr a i n
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast–iron. Pins and
journals are graded for correct size selection for their
bearing.
Engine Lubrication
The oil discharged by a trochoid–type oil pump driven by
the crankshaft is fed through full–flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.

6A–4
ENGINE MECHANICAL
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Condition
Possible causeCorrection
Headlights go out or dim
considerably
Battery run down or under chargedRecharge or replace battery
considerablyTerminals poorly connectedClean battery posts and terminals
and connect properly
Starting motor coil circuit shortedOverhaul or replace
Starting motor defectiveOverhaul or replace
2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect an igniton coil from any spark plug. Connect
the spark plug tester 5–8840–0607–0, start the engine,
a n d c h e c k i f a s p a r k i s g e n e r a t e d in t h e s p a r k p l u g t e s t e r.
Before starting the engine, make sure that the spark plugtester is properly grounded. To avoid electrical shock, do
not touch the part where insulation of the igniton coil is
broken while the engine is running.
Condition
Possible causeCorrection
Spark jumps across gapSpark plug defectiveClean, adjust spark gap or replace
Ignition timing incorrectRefer to Ignition System
Fuel not reaching fuel injector(s) or
engineRefer to item 3 (Trouble in fuel
system)
Valve timing incorrectAdjust
Engine lacks compressionRefer to item 4 (Engine lacks
compression)
No sparking takes placeIgnition coil disconnected or brokenConnect properly or replace
Electronic Ignition System with
moduleReplace
Poor connections in engine harnessCorrect
Powertrain Control Module cable
disconnected or defectiveCorrect or replace
3. Trouble In Fuel System
Condition
Possible causeCorrection
Starting motor turns over and spark
occurs but engine does not start
Fuel tank emptyFill
occurs but engine does not start.Water in fuel systemClean
Fuel filter cloggedReplace filter
Fuel pipe cloggedClean or replace
Fuel pump defectiveReplace
Fuel pump circuit openCorrect or replace
Evaporative Emission Control
System circuit cloggedCorrect or replace
Multiport Fuel Injection System faultyRefer to “Electronic Fuel Injection”
section

6A–7
ENGINE MECHANICAL
Condition CorrectionPossible cause
OthersEngine lacks compressionRefer to “Hard Start”
Valve incorrectly seatedLap valve
Air Cleaner Filter cloggedReplace filter element
Valve timing incorrectReadjust
Idle air control valve brokenReplace
Fast idle solenoid defectiveReplace
Positive Crankcase Ventilation valve
defective or cloggedReplace
Rough Engine Running
ConditionPossible causeCorrection
Engine misfires periodicallyIgnition coil layer shortedReplace
Spark plugs foulingClean or install hotter type plug
Spark plug(s) insulator nose leakingReplace
Fuel injector(s) defectiveReplace
Powertrain control module faultyReplace
Engine knocks periodicallySpark plugs running too hotInstall colder type spark plugs
Powertrain control module faultyReplace
Engine lacks powerSpark plugs fouledClean
Fuel injectors defectiveReplace
Mass Airflow Sensor or Intake
Airflow Sensor circuit defectiveCorrect or replace
Manifold Absolute Pressure (MAP)
Sensor or Manifold Absolute
Pressure Sensor circuit defectiveCorrect or replace
Engine Coolant Temperature Sensor
or Engine Coolant Temperature
Sensor circuit defectiveCorrect or replace
Powertrain Control Module faultyReplace
Intake Air Temperature Sensor or
Intake Air Temperature Sensor
circuit defectiveCorrect or replace
Throttle Position Sensor or Throttle
Position Sensor circuit defectiveCorrect or replace
Knock Sensor or Knock Sensor
circuits defectiveCorrect or replace
Knock Sensor Module or Knock
Sensor Module circuits defectiveCorrect or replace

6A–8
ENGINE MECHANICAL
Hesitation
ConditionPossible causeCorrection
Hesitation on accelerationThrottle Position Sensor adjustment
incorrectReplace throttle valve assembly
Throttle Position Sensor circuit open
or shortedCorrect or replace
Excessive play in accelerator linkageAdjust or replace
Mass Airflow Sensor circuit open or
poor connectionsCorrect or replace
Mass Airflow Sensor defectiveReplace
Manifold Absolute Pressure (MAP)
Sensor circuit open or shortedCorrect or replace
MAP Sensor defectiveReplace
Intake Air Temperature (IAT) Sensor
circuit open or shortedCorrect or replace
Knock Sensor (KS) Circuit open or
poor connectionsCorrect or replace
KS defectiveReplace
KS Module circuits open or shortedCorrect or replace
KS Module defectiveReplace
IAT Sensor defectiveReplace
Hesitation at high speedsFuel tank strainer cloggedClean or replace
(Fuel pressure too low)Fuel pipe cloggedClean or replace
Fuel filter cloggedReplace
Defective fuel pump systemCheck and replace
Fuel Pressure Control Valve leakingReplace
Hesitation at high speeds
(Fuel injector not working normally)Power supply or ground circuit for
Multiport Fuel Injection System
shorted or openCheck and correct or replace
Fuel Injector defectiveReplace
Cable of Multiport Fuel Injection
System circuit open or poor
connectionsCorrect or replace

6A–10
ENGINE MECHANICAL
Engine Lacks Power
ConditionPossible causeCorrection
Trouble in fuel systemFuel Pressure Control Valve not
working normallyReplace
Fuel injector cloggedClean or replace
Fuel pipe cloggedClean
Fuel filter clogged or fouledReplace
Fuel pump drive circuit not working
normallyCorrect or replace
Fuel tank not sufficiently breathing
due to clogged Evaporative
Emission Control System circuitClean or replace
Water in fuel systemClean
Inferior quality fuel in fuel systemUse fuel of specified octane rating
Powertrain Control Module supplied
poor voltageCorrect circuit
Throttle Position Sensor cable
broken or poor connectionsCorrect or replace
Throttle Position Sensor defectiveReplace
Mass Airflow Sensor not working
normallyReplace
Manifold Absolute Pressure Sensor
not working normallyReplace
Intake Air Temperature Sensor not
working normallyReplace
Engine Coolant Temperature Sensor
circuit open or shortedCorrect or replace
Engine Coolant Temperature Sensor
defectiveReplace
Powertrain Control Module defectiveReplace
Trouble in intake or exhaust systemAir Cleaner Filter cloggedReplace filter element
Air duct kinked or flattenedCorrect or replace
Ignition failure————Refer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequateInstall spark plugs of adequate heat
range
Ignition coil defectiveReplace