Electrical OPEL FRONTERA 1998 Workshop Manual

6E–195 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Lubrication System Trouble
StepNo Ye s Va l u e ( s ) Action
111. Check cylinder head & cam carrier gaskets for
damage.
2. If a problem is found, repair or replace as
necessary.
Was a problem found?
—Verify repairGo to Step 12
121. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Te c h 2 d a t a
Freeze Frame data/Failure Records butter
All electrical connections within a suspected
circuit and/or system
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repair
Contact
Te c h n i c a l
Assistance

6E–196
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
QOS System Doesn’t Work
StepActionVa l u e ( s )Ye sNo
1Was OBD System check performed?
—Go to Step 2
Go to OBD
System
Check
2Check glawplug indicator light. If bulb is broken,
replace.
Was a problem found?
—Verify repairGo to Step 3
31. Connect a circuit tester between glawplug & engine
ground.
2. With ignition on and engine off, check if the glaw
indicator and circuit tester indicate power voltage
for 9 to 13 sec. If not indicated, repair terminal & wire
harness.
Was repair needed?
—Verify repairGo to Step 4
41. Connect a circuit tester between glawplug and
engine ground.
2. With engine on, check if voltage continues for 180
sec. If not, inspect and repair glaw relay.
Was repair needed?
—Verify repairGo to Step 5
51. Remove the glawplug, and if damaged, replace.
2. Check glawplug resistance.
Was resistance as specified?
0.8 – 1Go to Step 7Go to Step 6
6Replace glawplug.
Was measure completed?
—Verify repairGo to Step 7
71. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Te c h 2 d a t a
Freeze Frame data/Failure Records butter
All electrical connections within a suspected
circuit and/or system
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repair
Contact
Te c h n i c a l
Assistance

6E–197 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Much Black Smoke in Exhaust Gas
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
In road tests, much black smoke is mixed.
Was OBD System check performed?
—Go to Step 2
Go to OBD
System
Check
21. Perform a bulletin research.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found?
—Verify repairGo to Step 3
31. Check if a correct fuel is used.
2. If a problem is found, change fuel.
Was a problem found?
—Verify repairGo to Step 4
41. Check air cleaner element for clogging.
2. If a problem is found, repair or replace as
necessary.
Was a problem found?
—Verify repairGo to Step 5
51. Connect Tech 2 to the vehicle.
2. Monitor data list to check injector function.
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 6
61. Connect Tech 2 to the vehicle.
2. Monitor RPCV test to check rpcv function.
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
71. Check valve clearance.
2. If a problem is found, adjust as necessary.
Was a problem found?
—Verify repairGo to Step 8
81. Review all diagnostic procedures in this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical check
Tech 2 data list
Freeze Frame data
All electrical connections in suspected circuits
& systems
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repair
Contact
Te c h n i c a l
Assistance

6E–198
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Excess Engine Oil Consumption
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Oil consumption measured in road tests is higher than
expected.
Was OBD System check performed?
—Go to Step 2
Go to OBD
System
Check
21. Perform a bulletin research.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found?
—Verify repairGo to Step 3
31. Check if a correct engine oil is used.
2. If a problem is found, change engine oil.
Was a problem found?
—Verify repairGo to Step 4
41. Check oil pipe connections for leakage.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 5
51. Check oil seals and gaskets for leakage.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 6
61. Connect Tech 2 to the vehicle.
2. Perform RPCV test to check its function.
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
71. Check piston ring for damage & groove wear.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 8
81. Check valve stem, valve guide and oil controller for
wear.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 9
91. Check camshaft carrier & cylinder head gaskets for
blow-by.
2. If a problem is found, repair or replace as
necessary.
Was a problem found?
—Verify repairGo to Step 10
101. Review all the diagnostic procedures in this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical check
Tech 2 data list
Freeze Frame data
All electrical connections in suspected circuits
& systems
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repair
Contact
Te c h n i c a l
Assistance

6E–199 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Default Matrix Table
Service Procedure Default Strategy
A referral strategy has been established to assist the
technician with additional information when the cause ofthe failure cannot be determined. If no problem is found
after performing diagnostics, then refer to the default
matrix table for further diagnostic information.
Default Matrix Table
Strategy Based Diagnostic ChartsInitial DiagnosisDefault Section(s)
On-Board Diagnostic (OBD) System
CheckVehicle does not enter diagnostics.Chassis Electrical
On-Board Diagnostic (OBD) System
CheckVehicle enters diagnostics and
communicates with the Tech 2. MIL is
“ON” in diagnostics. Engine does not
start and run.HEUI System Check
On-Board Diagnostic (OBD) System
CheckEngine starts and runs, no ECM codes
set. Customer complains of vibration.—
On-Board Diagnostic (OBD) System
CheckEngine starts and runs, no ECM codes
set. Customer complains of harsh or
soft shift, poor performance, delayed or
no engagement into drive or reverse,
transmission fluid leak, transmission
noise or vibration, or improper TCC
operation.Automatic Transmission
ECM Power and Ground CheckOn-Board Diagnostic (OBD) System
Check.Chassis Electrical
ECM Power and Ground CheckOn-Board Diagnostic (OBD) System
Check. ECM power and ground circuits
OK. Data link voltage incorrect.Chassis Electrical
On-Board Diagnostic (OBD) System
CheckEngine starts and runs, no ECM codes
set. Customer complains of harsh or
soft shift, poor performance, delayed or
no engagement into drive or reverse,
transmission fluid leak, transmission
noise or vibration, or improper TCC
operation.Automatic Transmission
SymptomsInitial DiagnosisDefault Section(s)
Intermittents1. On-board diagnostic (OBD)
system check.
2. Careful visual/physical inspections.Chassis Electrical
Hard Starts1. OBD system check.
2. Sensors (ECT, MAP, EGR, AP) ;
output chart.
3. Fuel system electrical test, fuel
system diagnosis.
4. Injector system.Engine Mechanical, Injector
System Check, Exhaust System
Diagnosis
Surges and/or Chuggles1. OBD system check.
2. Fuel system diagnosis.
3. Injector system.Calibration ID “Broadcast”
/Service Bulletins, Ignition
System Check, Generator
Output, Exhaust System
Diagnosis
Lack of Power, Sluggish or Spongy1. OBD system check.
2. Fuel system diagnosis.
3. Injector system.Refer to Exhaust System in
Engine Exhaust, TCC
Operation, Calibration
ID/Service Bulletins

6E–200
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
SymptomsInitial DiagnosisDefault Section(s)
Hesitation, Sag, Stumble1. OBD system check.
2. AP.
3. MAP output check.
4. Fuel system diagnosis.
5. Injector system.Generator Output Voltage (refer
to
Chassis Electrical),
Calibration ID/Service Bulletins,
Ignition System Check
Rough, Unstable, or Incorrect Idle,
Stalling1. OBD system check.
2. Fuel injector test.MAP Output Check, Throttle
Linkage, A/C Clutch Control
Circuit Diagnosis, Calibration
ID/Service Bulletins, Generator
Output Voltage (refer to
Chassis
Electrical
), Exhaust Diagnosis
Poor Fuel Economy1. OBD system check.
2. Careful visual/physical inspection.
3. Injector system.
4. Cooling system.TCC Operation, Exhaust
System (refer to
Engine
Exhaust
)
Engine Cranks But Will Not Run1. OBD system check.Fuel System Electrical
Diagnosis, Fuel System
Diagnosis, Fuel Injector Test.
Excessive Exhaust Emissions or
Odors1. OBD system check.
2. Emission test.
3. Cooling system.
4. Fuel system diagnosis.
5. Fuel injector test.
6. Injector system.
7. MAP output check.Exhaust Diagnosis, Calibration
ID/Service Bulletins
Dieseling, Run-On1. OBD system check.
2. Careful visual/physical inspection.
3. Fuel system diagnosis.—

6E–201 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
On–Vehicle Service
Camshaft Position (CMP)
Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector to the CMP
sensor.
035RW071
3. Remove the CMP sensor retaining bolt from the
cylinder head cover.
035RW075
Inspection Procedure
1. Inspect the sensor O-ring for cracks or leaks.
2. Replace the O-ring if it is worn or damaged.
3. Lubricate the new O-ring with engine oil.
4. Install the lubricated O-ring.
Installation Procedure
1. Install the CMP sensor in the cylinder head cover.
2. Install the CMP sensor retaining bolt.
Tighten
Tighten the retaining bolt to 9 Nꞏm (78 lb in.).
035RW075
3. Connect the electrical connector to the CMP sensor.
035RW071
4. Connect the negative battery cable.

6E–202
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Crankshaft Position (CKP)
Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the under cover.
035RW091
3. Disconnect the electrical connector to the CKP
sensor.
4. Remove one bolt and the CKP sensor from the left
side of the engine block.
NOTE: Use caution to avoid any hot oil that might drip
out.
035RW090
Inspection Procedure
1. Inspect the sensor O-ring for cracks or leaks.
2. Replace the O-ring if it is worn or damaged.
3. Lubricate the new O-ring with engine oil.
4. Install the lubricated O-ring.
Installation Procedure
1. Install the CKP sensor in the engine block.
2. Install the CKP sensor mounting bolt.
Tighten
Tighten the mounting bolt to 9 Nꞏm (78 lb in.).
035RW090
3. Connect the electrical connector to the CKP sensor.
4. Install the under cover.
035RW091
5. Connect the negative battery cable.

6E–203 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Engine Coolant Temperature
(ECT) Sensor
Removal Procedure
NOTE: Care must be taken when handling the engine
coolant temperature (ECT) sensor. Damage to the ECT
sensor will affect proper operation of the fuel injection
system.
1. Disconnect the negative battery cable.
2. Drain the radiator coolant. Refer to
Draining and
Refilling Cooling System
in Engine Cooling.
3. Disconnect the electrical connector.
4.Remove the ECT sensor from the front side of the
intake manifold.
035RW058
Installation Procedure
1. Apply sealer (LOCTITE 262) or the equivalent to the
threads of the ECT sensor.
2. Install the ECT sensor in the front side of the intake
manifold.
Tighten
Tighten the ECT sensor to 19 Nꞏm (14 lb ft.).
3. Connect the electrical connector.
035RW058
4. Fill the radiator with coolant. Refer to Draining and
Refilling Cooling System
in Engine Cooling.
5. Connect the negative battery cable.
Intake Air Temperature (IAT)
Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector from the IAT
sensor.
3. Remove the IAT sensor from the intake air duct by
using a rocking motion while pulling the sensor.
035RW056

6E–204
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Install the IAT sensor into the grommet in the intake
air duct.
035RW056
2. Correct the IAT electrical connector.
3. Connect the negative battery cable.
Manifold Absolute Pressure
(MAP) Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the EGR valve.
035RW054
3. Disconnect the MAP sensor connector from the MAP
sensor.
035RW053
4.Remove the bolts and the MAP sensor from the
intake manifold.
035RW057