change time OPEL FRONTERA 1998 Owner's Guide
Page 1460 of 6000
6E–343 ENGINE DRIVEABILITY AND EMISSIONS
constant measuring and adjusting of the air/fuel ratio, the
fuel injection system is called a “closed loop” system.
The PCM monitors signals from several sensors in order
to  determine  the  fuel  needs  of  the  engine.  Fuel  is
delivered under one of several conditions called “modes.”
All modes are controlled by the PCM.
Fuel Pressure Regulator
The  fuel  pressure  regulator  is  a  diaphragm-operated
relief  valve  mounted  on  the  fuel  rail  with  fuel  pump
pressure on one side and manifold pressure on the other
side.    The  fuel  pressure  regulator  maintains  the  fuel
pressure  available  to  the  injector  at  three  times
barometric pressure adjusted for engine load.  It may be
serviced separate.
If the pressure is too low, poor performance and a DTC
P0131, DTC P0151,DTC P0171 or DTC P1171 will be the
result.  If the pressure is too high, excessive odor and/or a
DTC P0132, DTC P0152,DTC P0172 or DTC P0175 will
be  the  result.    Refer  to 
Fuel  System  Diagnosis for
information on diagnosing fuel pressure conditions.
0011
Fuel Pump Electrical Circuit
When the key is first turned “ON,” the PCM energizes the
fuel  pump  relay  for  two  seconds  to  build  up  the  fuel
pressure  quickly.    If  the engine  is  not  started within two
seconds, the PCM shuts the fuel pump off and waits until
the engine is cranked.  When the engine is cranked and
the 58 X crankshaft position signal has been detected by
the PCM, the PCM supplies 12 volts to the fuel pump relay
to energize the electric in-tank fuel pump.
An inoperative fuel pump will cause a “no-start” condition.
A fuel pump which does not provide enough pressure will
result in poor performance.
Fuel Rail
The  fuel  rail  is  mounted  to  the  top  of  the  engine  and
distributes  fuel  to  the  individual  injectors.    Fuel  is
delivered to the fuel inlet tube of the fuel rail by the fuel
lines.    The  fuel  goes  through  the  fuel  rail  to  the  fuel
pressure regulator.  The fuel pressure regulator maintainsa constant fuel pressure at the injectors.  Remaining fuel
is then returned to the fuel tank.
055RW009
Idle Air Control (IAC) Valve
The purpose of the idle air control (IAC) valve is to control
engine idle speed, while preventing stalls due to changes
in  engine  load.    The  IAC  valve,  mounted  in  the  throttle
body,  controls  bypass  air  around  the  throttle  plate.    By
moving the conical valve (pintle) in (to decrease air flow)
or out  (to increase air flow), a controlled amount of air can
move around the throttle plate.  If the RPM is too low, the
PCM  will  retract  the  IAC  pintle,  resulting  in  more  air
moving past the throttle plate to increase the RPM.  If the
RPM  is  too  high,  the  PCM  will  extend  the  IAC  pintle,
allowing  less  air  to  move  past  the  throttle  plate,
decreasing the RPM.
The IAC pintle valve moves in small steps called counts.
During  idle,  the  proper  position  of  the  IAC  pintle  is
calculated by the PCM based on battery voltage, coolant
temperature, engine load, and engine RPM.  If the RPM
drops  below  a  specified  value,    and  the  throttle  plate  is
closed, the PCM senses a near-stall condition. The PCM
will  then  calculate  a  new  IAC  pintle  valve  position  to
prevent stalls.
If the IAC valve is disconnected and reconnected with the
engine running, the idle RPM will be wrong.  In this case,
the IAC must be reset.  The IAC resets when the key is
cycled  “ON”  then  “OFF.”    When  servicing  the  IAC,  it
should  only  be  disconnected  or  connected  with  the
ignition “OFF.”
The position of the IAC pintle valve affects engine start-up
and the idle characteristics of the vehicle.  If the IAC pintle
is fully open, too much air will be allowed into the manifold.
This results in high idle speed, along with possible hard
starting  and  a  lean  air/fuel  ratio.    DTC  P0507  or  DTC
P1509 may set.  If the IAC pintle is stuck closed, too little
air will be allowed in the manifold.  This results in a low idle
speed, along with possible hard starting and a rich air/fuel
ratio.    DTC  P0506  or  DTC  P1508  may  set.    If  the  IAC
pintle is stuck part-way open, the idle may be high or low
and will not respond to changes in the engine load. 
Page 1736 of 6000
ENGINE MECHANICAL 6A – 3
SERVICE INFORMATION
MAIN DATA AND SPECIFICATION
Engine type Diesel, four cycle water cooled inline
Camshaft type DOHC
Number of cylinders 4
Bore x stroke (mm) 95.4 x 104.9
Total piston displacement (cc) 2999
Compression ratio (to 1) 19.0
For Europe : 18.5
Engine weight (dry) N (kg/lb) 2492 (254/560) (A/T)
For Europe : 2422 (247/545) (A/T)
2649 (270/593) (M/T)
For Europe : 2697 (275/606) (M/T)
Engine idling speed (Reference) RPM 720
Compression pressure kpa (kg/cm
2/psi)-rpm 3040 (31/441)-200
Firing order 1–3–4–2
VALVE SYSTEM
Intake valves open at: B.T.D.C. 3°
close at: A.B.D.C. 57.6°
Exhaust valves open at: B.B.D.C. 56.5°
close at: A.T.D.C. 5°
Valve clearance (at cold) mm (in)
intake: 0.15 (0.006)
exhaust: 0.25 (0.01)
Oil filter Full flow and bypass combined type
Oil capacity (Original factory fill or rebuilt engine) 9.0 liters (7.9 US quarts)
Oil capacity (Service change)
with filter change 6.0 liters (6.3 US quarts)
without filter change 5.0 liters (5.3 US quarts)
Oil cooler Water cooled type
Inter cooler Air cooled type
Turbocharger method
Control method Wastegate control
Lubrication Pressurized control
Cooling method Coolant cooled
Crankshaft
As tufftriding (Nitrizing treatment) is applied to increase
crankshaft  strength,  crankpins  and  journals  should  not
be reground.
Piston Cooling
An oiling jet device for piston cooling is provided in the
lubricating  oil  circuit  from  the  cylinder  block  oil  gallery
via a check valve.
Take care not to damage any oiling jet when removing
and installing piston and connecting assembly.
Fuel Injection System
The injection system is oil rail type.
Quick On Start 4 System
QOS4  preheating  system  which  features  a  quick-on
glow plug with thermometer control of the glowing time
and the afterglow time function, is applied. 
Page 1804 of 6000
ENGINE MECHANICAL 6A – 71
12. Immediately  install  high  pressure  oil  pipe  and
tighten to specified torque.
Torque: 80 Nꞏm (8.1 kgꞏm / 57.9 lb ft)
13. Install cylinder head noise insulator cover.
Refer to “Cylinder Head” in this manual.
14. Install intercooler assembly.
Refer to “Intercooler” in this manual.
15. Install air cleaner cover and air duct.
16. Use TECH2 to rewrite injector data to ECM.
For  rewriting  method  refer  to  section  “Data
Programming in Case of ECM Change” of 6E 4JX1
engine driveability and emissions in this manual.
NOTE:
1) On  completion  of  servicing,  bleed  air  from  the
engine inside fuel passage by means of the priming
pump. (The priming pump should be operated more
times than in the case of conventional engines.)
2) As air is in the oil rail, it takes more time to start the
engine.  Rough  idling  may  occur  while  the  air  is
being bled completely after starting the engine, but
it does not indicate trouble.
The air will be bled and normal engine status will be
reached  while  the  vehicle  is  driven  for  about  5  km
or engine is operated for about 5 minutes at 1500 to
2000 rpm.
3) The  injector  spare  part  will  be  provided  for  group
number B1, B2 and B3 only. 
Page 1838 of 6000
ENGINE COOLING  6B – 5
ENGINE COOLANT CHANGE
PROCEDURE
1. To  change  engine  coolant,  make  sure  that  the
engine is cool.
WARNING:
When  the  coolant  is  heated  to  a  high  temperature,
be  sure  not  to  loosen  or  remove  the  radiator  cap.
Otherwise  you  might  get  scalded  by  hot  vapor  or
boiling water. To open the radiator cap, put a piece
of thick cloth on the cap and loosen the cap slowly
to  reduce  the  pressure  once  the  coolant  has
become cooler.
2. Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
NOTE: For best results it is suggested that the engine
cooling  system  be  flushed  at  least  once  a  year.  It  is
advisable  to  flush  the  interior  of  the  cooling  system
including  the  radiator  before  using  anti-freeze
(ethylene-glycol based).
Replace  damaged  rubber  hoses  as  the  engine  anti-
freeze coolant is liable to leak out even minor cracks.
Isuzu  recommends  using  Isuzu  genuine  anti-freeze
(ethylene-glycol  based)  or  equivalent,  for  the  cooling
system and not add any inhibitors or additives.
CAUTION:
A failure  to  correctly  fill  the engine cooling system
in changing  or  topping off  coolant  may  sometimes
cause  the  coolant  to  overflow  from  the  filler  neck
even before the engine and radiator are completely
full.
If the engine runs under this condition, shortage of
coolant  may  possibly  result in  engine  overheating.
To  avoid  such  trouble,  the  following  precautions
should be taken in filling the system.
3. To refill engine coolant, pour coolant up to filler neck
using  a  filling  hose  which  is  smaller  in  outside
diameter than the filler neck. Otherwise air between
the  filler  neck  and  the  filling  hose  will  block  entry,
preventing the system from completely filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling over
this  maximum  rate  may  force  air  inside  the  engine
and radiator.
And also, the coolant overflow will increase, making
it difficult to determine whether or not the system is
completely full.
5. After  filling  the  system  full,  pull  out  the  filling  hose
and  check  to  see  if  air  trapped  in  the  system  is
dislodged and the coolant level goes down. Should
the  coolant  level  go  down,  repeat  topping-off  until
there is no more drop in the coolant level.
6. Directly  after  filling  the  radiator,  fill  the  reservoir  to
the maximum level.
7. Install and tighten radiator cap and start the engine.
After  idling  for  2  to  3  minutes,  stop  the  engine  and
reopen  radiator  cap.  If  the  water  level  is  lower,
replenish.WARNING:
When  the  coolant  is  heated  to  a  high  temperature,
be  sure  not  to  loosen  or  remove  the  radiator  cap.
Otherwise  you  might  get  scalded  by  hot  vapor  or
boiling water. To open the radiator cap, put a piece
of thick cloth on the cap and loosen the cap slowly
to  reduce  the  pressure  once  the  coolant  has
become cooler.
8. After tightening radiator cap, warm up the engine at
about 2,000 rpm.
Set  heater  adjustment  to  the  highest  temperature
position,  and  let  the  coolant  circulate  also  into
heater water system.
9. Check  to  see  the  thermostat  has  opened  by  the
needle  position  of  a  water  thermometer,  conduct  a
5-minute idle again and stop the engine.
10. When the engine has been cooled, check filler neck
for  water  level  and  replenish  if  required.  Should
extreme  shortage  of  coolant  be  found,  check  the
coolant system and reservoir tank hose for leakage.
11. Fill  the  coolant  into  the  reservoir  tank  up  to  “MAX”
line. 
Page 1856 of 6000
ENGINE FUEL 6C – 11
8. Install  injector  harness  assembly,  reconnect
harness connecter to injector.
9. Record  the  identification  marking  of  injector  for
each cylinder that is indicated on the upper portion
of injector.
Legend
(1) Part Number
(2) Category Number (Grade code)
(3) Serial Number
(4) Bar Code
10. Install cylinder head assembly.
Refer to “Cylinder Head” in this manual.
11. Fill  with  about  300cc  of  engine  oil  from  the  high
pressure oil pipe installation port of the oil rail using
an oil filler.
If  assembled  without  filling  the  oil  rail  with  oil,  the
time for engine starting will be longer.
12. Immediately  install  high  pressure  oil  pipe  and
tighten to specified torque.
Torque: 80 Nꞏm (8.1 kgꞏm / 57.9 lb ft)
13. Install cylinder head noise insulator cover.
Refer to “Cylinder Head” in this manual.
14. Install intercooler assembly.
Refer to “Intercooler” in this manual.
15. Install air cleaner cover and air duct.
16. Use TECH2 to rewrite injector data to ECM.
For  rewriting  method  refer  to  section  “Data
Programming  in  Case  of  ECM  Change”  of  section
6E  4JX1  engine  driveability  and  emissions  in  this
manual.NOTE:
1) On  completion  of  servicing,  bleed  air  from  the
engine inside fuel passage by means of the priming
pump. (The priming pump should be operated more
times than in the case of conventional engines.)
2) As air is in the oil rail, it takes more time to start the
engine.  Rough  idling  may  occur  while  the  air  is
being bled completely after engine start, but it does
not indicate trouble.
The air will be bled and normal engine status will be
reached  while  the  vehicle  is  driven  for  about  5  km
or engine is operated for about 5 minutes at 1500 to
2000 rpm.
3) The  injector  spare  part  will  be  provided  for  group
number B1, B2 and B3 only.
Injector Grade code Programming
(Injector Change)
In  case  of  an  injector  change,  the  injector  grade  code
(category number) must be programmed by Tech-2.
Programming Procedure
1. Connect the Tech-2 to the vehicle DLC.
2. Turn the starter switch to the “ON” position.
3. Select the “Diagnosis” from the Main menu.
4. Select  the  “Programming”  from  the  Application
menu.
1
4
32
055RW00001
F0 : Diagnostic C ode
F1 : Data Display
F2 : Snapshot
F3 : Miscellaneous Test
F4 : ProgrammingA pplication Menu
035RW00002 
Page 1888 of 6000
ENGINE ELECTRICAL 6D – 21
Rectifier Assembly
1. Measure  the  resistance  between  each  diode
terminal  and  aluminum  diode  fin  in  forward  and
reverse directions  with  the  connection  of  the tester
leads switched. The diodes are normal if resistance
is nearly zero ohms in one direction and is infinitely
high in the other direction.
2. If  a  diode  has  no  resistance  or  equal  resistance  in
both  directions,  it  is  defective  and  should  be
replaced together with the holder.
IC Regulator Assembly
Connect  a  variable  resistor,  two  12V  batteries,  a  fixed
resistor, and a voltmeter to the IC regulator as shown in
illustration.
a. Measuring equipment specifications
1. Fixed resistor (R1) : 10 Ohms / 3W
2. Variable resistor (Rv) : 0 – 300 Ohms / 12W
3. Batteries (BAT1, BAT2) : 12V (2 Batteries)
4. DC voltmeter : 0 – 50V / 0.5 steps (4 Check points)
b. Measuring procedure
1. Measure  the  voltage  “V1”  across  the  first  battery
(BAT1).  If  the  reading  is  between  10  and  13  volts,
the battery is normal.
2. Measure the voltage “V3” across both the batteries
(BAT1,  BAT2).  If the reading is between 20 and 26
bolts, the batteries are normal.
3. Gradually  increase  the  resistance  of  the  variable
resistor  from  zero.  Measure  the  voltage  “V2”  (the
voltage across the F and E terminals).
Check to see that the voltage across “V1” changes
at  this  time.  If  there  is  no  change,  the  voltage
regulator is faulty and must be replaced.
4. Measure the voltage at “V4” (the voltage across the
variable  resistor  center  tap  and  terminal  E  with the
variable  resistor  resistance  held  constant).  The
measure  voltage  should  be  within  the  specified
(14.4  ± 0.3  volts)  limits.  If  it  is  not,  the  regulator
must be replaced.
Reassembly
To  reassemble,  follow  the  disassembly  steps  in  the
reverse order, noting the following points:
NOTE:
1) Never  make  battery  connections  with  polarities
reversed, or battery will be shorted via the diodes.
This will cause damage to the diodes.
2) Do not connect generator B terminal to ground; it is
connected directly to the battery.
This cable will burn if it is connected to ground.
3) Make sure to disconnect the positive (+) terminal of
the battery when quick-charging battery.
Diodes  may  be  damaged  due  to  abnormal  pulse
voltage generated by the quick charger.
4) When  reassembling  the  front  section  to  rear
section,  insert  a  stiff  wire  into  hole  in  the  rear  face
of the rear cover from the outboard side to support
the  brush  in  raised  position,  then  insert  the  front
section to which rotor is assembled.
5) Reassemble  parts  carefully  to  be  sure  they  fit  into
their  original  position,  paying  attention  to  the
insulated portions.
6) Wipe  insulating  tubes,  washers  and  plates  clean
and install them in position carefully to avoid getting
oil or grease on them.
066RS036
R
EBS
R1RV
BAT2 BAT1
V2V3
V4V1+
−
+
−
066RW029 
Page 1890 of 6000
ENGINE ELECTRICAL 6D – 23
QOS4 PREHEATING SYSTEM
GENERAL DESCRIPTION
QOS4 preheating system features a quick-on glow plug
with  thermometer  control  of  the  glowing  time  and  the
afterglow time function.
The  system  consists  of  the  ECM,  indicator  lamp,  ECT
sensor,  vehicle  speed  sensor,  relay  and  temperature
self-control type glow plugs.With the employment of the ECT sensor, the glow time
changes  according  to  the  engine  coolant  temperature,
thus  allowing  optimum  starting  conditions  to  be
obtained.
The after glow time function is controlled by ECM.
NOTE:
Refer to DTC P0380 and P0381 of 6E section.
SYSTEM DIAGRAM
+
-KEY
50A
ECM
50A
GLOW
50A
2
WHT/
RED
0.5
BLK/
BLU
ECM J1-15 3
WHT/
RED
3
RED/
BLKMAIN
80A
8BLK/RED
Glow
Relay
GLOW PLUG   4
BATTHeater & A/C
Relay
060RW132 
Page 1918 of 6000
6E–25 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
General Service Information
Serviceability Issues
Non-OEM Parts
All  of  the  OBD  diagnostics  have  been  calibrated  to  run
with OEM parts.  Accordingly, if commercially sold sensor
or switch is installed, it makes a wrong diagnosis and turn
on the MIL (“Check Engine” lamp).
Aftermarket  electronics,  such  as  cellular  phones,
stereos, and anti-theft devices, may radiate EMI into the
control system if they are improperly installed.  This may
cause a false sensor reading and turn on the MIL (“Check
Engine” lamp).
Poor Vehicle Maintenance
The  sensitivity  of  OBD  diagnostics  will  cause  the  MIL
(“Check  Engine”  lamp)  to  turn  on  if  the  vehicle  is  not
maintained properly.  Restricted oil filters, fuel filters, and
crankcase deposits due to lack of oil changes or improper
oil viscosity can trigger actual vehicle faults that were not
previously  monitored  prior  to  OBD.    Poor  vehicle
maintenance  can  not  be  classified  as  a  “non-vehicle
fault”, but with the sensitivity of OBD diagnostics, vehicle
maintenance schedules must be more closely followed.
Related System Faults
Many  of  the  OBD  system  diagnostics  will  not  run  if  the
ECM detects a fault on a related system or component.
Visual/Physical Engine Compartment
Inspection
Perform  a  careful    visual  and  physical  engine
compartment inspection when performing any diagnostic
procedure  or  diagnosing  the  cause  of  an  emission  test
failure.  This can often lead to repairing a problem without
further steps.  Use the following guidelines when
performing a visual/physical inspection:
Inspect  all  vacuum  hoses  for  punches,  cuts,
disconnects, and correct routing.
Inspect  hoses  that  are  difficult  to  see  behind  other
components.
Inspect all wires in the engine compartment for proper
connections, burned or chafed spots, pinched wires,
contact with sharp edges or contact with hot exhaust
manifolds or pipes.
Basic Knowledge of Tools Required
NOTE: Lack of basic knowledge of this powertrain when
performing  diagnostic  procedures  could  result  in  an
incorrect  diagnosis  or  damage  to  powertrain
components.    Do  not  attempt  to  diagnose  a  powertrain
problem without this basic knowledge.
A basic understanding of hand tools is necessary to effec-
tively use this section of the Service Manual.
Serial Data Communications
Class II Serial Data Communications
This vehicle utilizes the “Class II” communication system.
Each bit of information can have one of two lengths: longor  short.    This  allows  vehicle  wiring  to  be  reduced  by
transmitting and receiving multiple signals over a single
wire.  The messages carried on Class II data streams are
also  prioritized.    If  two  messages  attempt  to  establish
communications on the data line at the same time, only
the message with higher priority will continue.  The device
with the lower priority message must wait.
On this vehicle the Tech 2 displays the actual values for
vehicle parameters.   It  will  not be  necessary to perform
any conversions from coded values to actual values.
On-Board Diagnostic (OBD)
On-Board Diagnostic Tests
A diagnostic test is a series of steps, the result of which is
a pass or fail reported to the diagnostic executive.  When
a  diagnostic  test  reports  a  pass  result,  the  diagnostic
executive records the following data:
The diagnostic test has been completed since the last
ignition cycle.
The  diagnostic  test  has  passed  during  the  current
ignition cycle.
The  fault  identified  by  the  diagnostic  test  is  not
currently active.
When a diagnostic test reports a fail result, the diagnostic
executive records the following data:
The diagnostic test has been completed since the last
ignition cycle.
The fault identified by the diagnostic test is currently
active.
The fault has been active during this ignition cycle.
The operating conditions at the time of the failure.
Comprehensive Component Monitor
Diagnostic Operation
Comprehensive  component  monitoring  diagnostics  are
required to operate engine properly.
Input Components:
Input components are monitored for circuit continuity and
out-of-range  values.    This  includes  rationality  checking.
Rationality checking refers to indicating a fault when the
signal  from  a  sensor  does  not  seem  reasonable.  Accel
Position (AP) sensor that indicates high throttle position
at  low  engine  loads  or  MAP  voltage.  Input  components
may include, but are not limited to the following sensors:
Intake Air Temperature (IAT) Sensor
Crankshaft Position (CKP) Sensor
Intake throttle Position (ITP) Sensor
Engine Coolant Temperature (ECT) Sensor
Camshaft Position (CMP) Sensor
Manifold absolute Pressure (MAP) Sensor
Accel Position Sensor
Fuel Temp Sensor
Rail Pressure Sensor
Oil Temp Sensor
EGR Pressure Sensor
Vehicle Speed Sensor 
Page 1925 of 6000
6E–32
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
DTC Modes
There are three options available in the Tech 2 DTC mode
to  display  the  enhanced  information  available.    A
description  of  the  new  modes,  DTC  Info,  follows.    After
selecting DTC, the following menu appears:
DTC Info
Clear Info
Read DTC Info Ordered By Priority
The  following  is  a  brief  description  of  each  of  the  sub
menus in DTC Info. The order in which they appear here is
alphabetical and not necessarily the way they will appear
on the Tech 2.
DTC Information Mode
Use  the  DTC  info  mode  to  search  for  a  specific  type  of
stored DTC information.The service manual may instruct
the  technician  to  test  for  DTCs  in  a  certain  manner.
Always follow published service procedures.
Fail This Ignition
This selection will display all DTCs that have failed during
the present ignition cycle.
History
This selection will display only D T C s  t h a t  a r e  s t o r e d  i n  t h e
ECM’s history memory.  It will not display Type B DTCs
that have not requested the MIL (“Check Engine” lamp).  It
will display all type A and B DTCs that have requested the
MIL and have failed within the last 40 warm-up cycles.  In
addition,  it  will  display  all type  C  and  type  D  DTCs  that
have failed within the last 40 warm-up cycles.
MIL SVC or Message Requested
This selection will display only DTCs that are requesting
the  MIL.  Type  C  and  type  D  DTCs cannot  be  displayed
using this option.  This selection will report type B DTCs
only after the MIL has been requested.
Test Failed Since Code Cleared
This selection will display all active and history DTCs that
have reported a test failure since the last time DTCs were
cleared.
Injector Test
This  test  is  conducted  to  make  it  sure  that  appropriate
electric  signals  are  being  sent  to  injectors  Nos.  1  –  4.
Tech–2 must be used for this test.
Test Procedure:
1. Connect Tech–2 to the vehicle DLC.
2. Set Ignition Switch to the “ON” position.
3. Select Control Test.
4. Select Injector Test.
5. Send instructions to each injector(Switch on), making
sure of injector working noise.
NOTE: If  injector  working  noise  (Clink)  can  hardly  be
confirmed,  remove  the  engine  head  cover  noise
insulation.
Refer to Section 6A.6. In  the  injector  whose  working  noise  has  been
confirmed,  its  electric  circuit  can  be  regarded  as
normal.
As for the injector whose working noise has not been
confirmed, its electric circuit or the injector proper is
faulty.
EGR Valve Test
This test is conducted to check EGR valve for its working.
This test needs Tech–2.
Test Procedure
1. Connect Tech–2 to vehicle DLC.
2. Switch on the engine.
3. Select “DIAGNOSIS” from the main menu.
4. Select Miscellaneous Test.
5. Select EGR Valve.
6. Instruct EGR Valve to check a data list.
7. If  change  in  the  data  list  shows  a  normal  valve,  the
working of EGR Valve can be judged to be normal.
Rail Pressure Control Valve Test
This test is conducted to check RPC valve for its working.
This test needs Tech–2.
Test Procedure
1. Connect Tech–2 to vehicle DLC.
2. Switch on the engine.
3. Select “DIAGNOSIS” from the main menu.
4. Select Miscellaneous Test.
5. Select Rail Pressure Control Valve.
6. Instruct RPC Valve to check a data list.
7. If  change  in  the  data  list  shows  a  normal  valve,  the
working of RPC Valve can be judged to be normal.
Injector Balance Test
This  test  is  conducted  to  make  it  sure  that  appropriate
electric signals are being sent to injectors Nos. 1-4, when
the engine is idling.
This test needs Tech–2.
Test Procedure
1. Connect Tech–2 to vehicle DLC.
2. The engine is running at idling condition.
3. Select “DIAGNOSIS” from the main menu.
4. Select Miscellaneous Test.
5. Select the injector Balance Test.
6. Send  instructions  to  each  injector(Switch  On),
making sure change of the engine vibration.
7. In the injector whose change of the vibration has been
confirmed,  it’s  electric  circuit  can  be  regarded  as
normal.
Data Programming in Case of ECM Change
When  replacing  ECM,  it  is  necessary  to  confirm  and
record  the  group  sign  of  injector  beforehand.  For  this
confirmation. 
Page 1934 of 6000
6E–41 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
EGR (Exhaust Gas Recirculation)
Diagnosis
A  diagnosis  of  the  EGR  system  is  covered  by  DTC
P1403.
EGR VSV circuit diagnosis is covered by DTC P1404.
EGR  pressure sensor  diagnosis  is  covered  by  DTC
P405 and/or P406.
EGR  EVRV  circuit  diagnosis  is  covered  by  DTC
P1405. Refer to the DTC charts.
Tech 2 Data Definitions and Ranges
A/C CLUTCH–Tech 2 Displays ON or OFF–
Indicates  whether  the  A/C  has  commanded  the  A/C
clutch ON.
MAP kPa — Tech 2 Range 10-105 kPa/0.00-5.00
Vo l t s   —
The  manifold  absolute  pressure  reading  is  determined
from the MAP sensor signal monitored during key up and
wide  open  throttle  (WOT)  conditions.    The  manifold
absolute  pressure  is  used  to  compensate  for  altitude
differences  and  is  normally  displayed  around  “61-104”
depending on altitude and manifold absolute pressure.
CMP ACT. COUNTER –Cam Position
DESIRED IDLE — Tech 2 Range 0-3187 RPM —
The idle speed that the ECM is commanding.  The ECM
will compensate for various engine loads based on engine
coolant temperature,  to keep the engine at the desired
speed.
ECT — (Engine Coolant Temperature) Tech 2
Range –40
C to 151C (–40F to 304F) —
The engine coolant temperature (ECT) is mounted in the
coolant  stream  and  sends  engine  temperature
information to the ECM.  The ECM applies 5 volts to the
ECT  sensor  circuit.    The  sensor  is  a  thermistor  which
changes  internal  resistance  as  temperature  changes.
When  the  sensor  is  cold  (high  resistance),  the  ECM
monitors a high signal voltage and interprets that as a cold
engine.    As  the  sensor  warms  (decreasing  resistance),
the voltage signal will decrease and the ECM will interpret
the lower voltage as a warm engine.
ENGINE RUN TIME — Tech 2 Range
00:00:00-99:99:99 Hrs:Min:Sec —
Indicates the time elapsed since the engine was started.
If the engine is stopped, engine run time will be reset to
00:00:00.
ENGINE SPEED — Range 0-9999 RPM —
Engine  speed  is  computed  by  the  ECM  from  the  57X
reference  input.    It  should  remain  close  to  desired  idle
under various engine loads with engine idling.Air Intake Valve meter POSITION — Tech 2 Range
0-100 % —
IAT (INTAKE AIR TEMPERATURE)— Tech 2 Range
–40
C to 151C (–40F to 304F) —
The  ECM  converts  the  resistance  of  the  intake  air
temperature  sensor  to  degrees.    Intake  air  temperature
(IAT) is used by the ECM to adjust fuel delivery and spark
timing according to incoming air density.
MAP — Tech 2 Range 10-105 kPa (0.00-4.97 Volts)—
The manifold absolute pressure (MAP) sensor measures
the change in the boost pressure.
MIL — Tech 2 Displays ON or OFF —
Indicates the ECM commanded state of the malfunction
indicator lamp.
AP — Tech 2 Range 0%-100% —
AP (Accelerator position)  angle is computed by the ECM
from  the  AP  sensor  voltage.    AP  angle  should  display
“0%” at idle and “100%” at wide open throttle.
AP SENSOR — Tech 2 Range 0.00-5.00 Volts —
The  voltage  being  monitored  by  the  ECM  on  the  AP
sensor signal circuit.
VEHICLE SPEED—Tech 2 Range 0-255 km/h (0-155
mph)–
The vehicle  speed  sensor signal  is  converted into km/h
and mph for display.
Typical Scan Data Values
Use  the  Typical  Scan  Data  Values  Table  only  after  the
On-Board  Diagnostic  System  Check  has  been
completed,  no  DTC(s)  were  noted,  and  you  have
determined that the on-board diagnostics are functioning
properly.  Tech 2 values from a properly-running engine
may  be  used  for  comparison  with  the  engine  you  are
diagnosing.    The  typical  scan  data  values  represent
values that would be seen on a normally-running engine.
NOTE: A Tech 2 that displays faulty data should not be
used, and the problem should be reported to the Tech 2
manufacturer.    Use  of  a  faulty  Tech  2  can  result  in
misdiagnosis and unnecessary replacement of parts.
Only  the  parameters  listed  below  are  referred  to  in  this
service  manual  for  use  in  diagnosis.    For  further
information on using the Tech 2 to diagnose the ECM and
related sensors, refer to the applicable reference section
listed  below.    If  all  values  are  within  the  typical  range
described  below,  refer  to  the 
Symptoms  section  for
diagnosis.
Test Conditions
Engine running, lower radiator hose hot, transmission in
park or neutral, accessaries off, brake not applied and air
conditioning off.