fuel OPEL FRONTERA 1998 Workshop Manual

ENGINE FUEL 6C – 17
INSPECTION AND REPAIR
The high pressure oil pump is made precisely,
therefore, disassembly is not recommended.
INSTALLATION
1. Set O-ring to high pressure oil pump assembly.
Install the pump assembly into the rear of timing
gear case.
Tighten nut to specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
Legend
(1) O-ring
(2) High Pressure Oil Pump Assembly
(3) Nuts
(4) O-ring
2. Tighten high pressure oil pump assembly bracket
together with two way valve bracket.
Torque: 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)Legend
(1) High Pressure Oil Pump Assembly
(2) Nut
(3) Two Way Valve Bracket
(4) Bolt
3. Install the pump gear to align timing mark with idle
gear A.
Tighten high pressure pump gear fixing bolt to the
specified torque.
Apply engine oil to thread and seat of bolt.
Torque: 75 Nꞏm (7.6 kgꞏm/55 lb ft)
Legend
(1) O-ring
(2) Pump Gear
(3) Bolt
(4) Timing Mark
1
2
43
040RW007
2
3
4 1
040RW006
4
GEAR:O/PUMP
IDLE GEAR A
1
2
3
040RW005

6C – 18 ENGINE FUEL
4. Remove lock bolt of idle gear A.
5. Install timing gear case cover.
Refer to “Timing gear” in this manual.
6. Install front plate.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
7. Install timing pulley of high pressure oil pump.
Torque: 10 Nꞏm (1.0 kgꞏm/7.2 lb ft)
8. Install timing belt and tighten timing belt tensioner
assembly.
Refer to “Cylinder head” in this manual.
Legend
(1) Align Mark
(2) Camshaft Pulley
(3) Timing Belt
(4) High Pressure Oil Pump Pulley
(5) Bolt
(6) Tensioner Assembly
(7) Tensioner Bolt
(8) Tensioner Spring
9. Install CMP sensor bracket.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
10. Connect CMP sensor cable.
11. Install timing belt cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
12. Fill with about 300 cc 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.
13. Immediately install high pressure oil pipe and
tighten to specified torque.
NOTE:
1) Use new O-ring.
2) Clean O-ring groove and fitting surface of parts.
3) Apply engine oil to O-ring.
Torque: 80 Nꞏm (8.1 kgꞏm/57.9 lb ft)14. Install the crankshaft damper pulley with specified
torque.
Torque: 220 Nꞏm (22 kgꞏm/159 lb ft)
15. Install the intercooler assembly.
Refer to “Intercooler” in this manual.
16. Install air cleaner cover and air duct.
1
2
3
8
67
4 5
F06RW055

ENGINE FUEL 6C – 19
HIGH PRESSURE OIL PIPE INSTALLATION
1. Install upper bracket to two way valve, tighten them
temporarily.
2. Install pipe A to two way valve, tighten pipe A
temporarily with union nut D.
3. Install two way valve assembly to cylinder block,
tighgten with union nut C temporarily.
4. Install pipe B to two way valve, tighten union nut E
and union nut F temporarily.
5. Tighten upper bracket to specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
6. Tighten union nut in the following order, union nut
C, D, F, and E to the specified torque.
Torque : 80 Nꞏm (8.1 kgꞏm/57.9 lb ft)
7. Tighten lower bracket to the specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
NOTE: Wash inside pipe, inside union nut and O-ring
seal surface to remove engine oil and foreign materials.
6
5
7
9
8
114
1
2
3 10
Legend
(1) Union Nut F
(2) Pipe B
(3) Union Nut E
(4) Upper Bracket
(5) Two Way Valve
(6) Union Nut D(7) Pipe A
(8) Union Nut C
(9) Lower Bracket
(10) To Oil Rail
(11) To High Pressure Oil Pump
052R200001

6C – 20 ENGINE FUEL
FUEL TANK
REMOVAL
1. Disconnect battery ground cable.
2. Remove fuel filler cap.
3. Drain fuel.
After drain the fuel tighten the drain plug with
specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14 lb ft)
4. Remove fuel filler hose and let air pull off hose.
5. Remove breather hose.
6. Remove fuel feed hose and fuel return hose.
7. Disconnect harness connector from fuel gauge unit.
8. Remove under cover.
9. Remove fuel tank assembly.
INSTALLATION
1. Fuel tank assembly.
1) Place a flange on right side of tank on the
bracket.
2) Install a flange to left side of the bracket from the
bottom, and tighten bolts to the specified torque.
Torque : 36 Nꞏm (3.7 kgꞏm/26.8 lb ft)
2. Install fuel hose and fuel return hose.
3. Install the breather hose.
4. Reconnect harness connector to fuel gauge unit.
5. Install under cover.
6. Install fuel filler hose and let air pull off hose.
7. Fill fuel tank with fuel and tighten filler cap.
8. Reconnect battery ground cable.
1
2
4
8
678 Europe, Nicaragua, Argentina, Philippin
6
5
3
Legend
(1) Fuel Tank Assembly
(2) Gauge Unit
(3) Bolt(4) Under Cover
(5) Bolt
(6) Fuel Filler Hose
(7) Fuel Filler Cap
(8) Breather Hose
140R200032

ENGINE FUEL 6C – 21
FUEL GAUGE UNIT
1
2
3
140R200033
REMOVAL
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.
3. Drain fuel.
After drain the fuel tighten the drain plug with
specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14 lb ft)
4. Disconnect harness connector from fuel gauge unit.
5. Fuel Gauge Unit
1) Remove the fixing screws, then the fuel gauge
unit.
INSTALLATION
1. Fuel Gauge Unit
2. Connect the harness connector to the fuel gage
unit.
3. Fill the tank with fuel and tighten fuel filler cap.
4. Connect battery ground cable.
FUEL FILLER CAP
The fuel filler cap contains a vacuum valve. If a
negative pressure develops in the fuel tank, the
external valve of the fuel filler cap opens to allow the
fresh air to flow into the fuel tank through the vacuum
valve.
INSPECTION
Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.Legend
(1) Vacuum Valve
(2) Pressure Valve
(3) Seal Ring Legend
(1) Fuel Tank Assembly
(2) Fuel Gauge Unit
(3) Drain Plug
1
3
2
060R200247

6E–6
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Removal Procedure 6E–212. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–212. . . . . . . . . . . . . . . . . .
Fuel Filter Cap 6E–213. . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6E–213. . . . . . . . . . . . . . . . . . . .
Inspection Procedure 6E–213. . . . . . . . . . . . . . . . . .
Fuel Filter 6E–213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation Procedure 6E–213. . . . . .
Fuel Gauge Unit 6E–213. . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–213. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–214. . . . . . . . . . . . . . . . . .
Fuel Injectors 6E–214. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation Procedure 6E–214. . . . . .
Fuel Temperature Sensor 6E–214. . . . . . . . . . . . . . . .
Removal Procedure 6E–214. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–215. . . . . . . . . . . . . . . . . .
Rail Pressure (RP) Sensor 6E–216. . . . . . . . . . . . . . .
Removal Procedure 6E–216. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–216. . . . . . . . . . . . . . . . . .
Fuel Tank 6E–216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–216. . . . . . . . . . . . . . . . . . . .
Throttle Body (TB) 6E–217. . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–217. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–217. . . . . . . . . . . . . . . . . .
Air Conditioning (A/C) Relay 6E–217. . . . . . . . . . . . . .
Removal Procedure 6E–217. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–217. . . . . . . . . . . . . . . . . .
Exhaust Gas Recirculation (EGR) Vacuum
Switch Valve (VSV) 6E–217. . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–217. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–218. . . . . . . . . . . . . . . . . .
Electronic Vacuum Regurating Valve (EVRV) 6E–219
Removal Procedure 6E–219. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–220. . . . . . . . . . . . . . . . . .
Wiring and Connectors 6E–220. . . . . . . . . . . . . . . . . . .
Wiring Harness Service 6E–220. . . . . . . . . . . . . . . .
Connectors and Terminals 6E–220. . . . . . . . . . . . . .
Wire Harness Repair: Twisted Shielded
Cable 6E–220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–220. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–221. . . . . . . . . . . . . . . . . .
Twisted Leads 6E–221. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–221. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–222. . . . . . . . . . . . . . . . . .
Weather-Pack Connector 6E–223. . . . . . . . . . . . . . . . .
Tools Required 6E–223. . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–223. . . . . . . . . . . . . . . . . . . . Installation Procedure 6E–223. . . . . . . . . . . . . . . . . .
Com-Pack III 6E–224. . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 6E–224. . . . . . . . . . . . . . . . . . . .
Metri-Pack 6E–224. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools Required 6E–224. . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–224
. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–224. . . . . . . . . . . . . . . . . .
General Description
(ECM and Sensors) 6E–225. . . . . . . . . . . . . . . . . . . . .
57X Reference ECM Input 6E–225. . . . . . . . . . . . . .
A/C Request Signal 6E–225. . . . . . . . . . . . . . . . . . . .
Crankshaft Position (CKP) Sensor 6E–225. . . . . . .
Camshaft Position (CMP) Sensor and
Signal 6E–225. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature (ECT) Sensor 6E–225
Electrically Erasable Programmable Read
Only Memory (EEPROM) 6E–225. . . . . . . . . . . . . .
Intake Air Temperature (IAT) Sensor 6E–225. . . . .
Manifold Absolute Pressure (MAP) Sensor 6E–226
Engine Control Module (ECM) 6E–226. . . . . . . . . . .
ECM Function 6E–226. . . . . . . . . . . . . . . . . . . . . . . . .
ECM Components 6E–226. . . . . . . . . . . . . . . . . . . . .
ECM Voltage Description 6E–226. . . . . . . . . . . . . . .
ECM Input/Outputs 6E–226. . . . . . . . . . . . . . . . . . . .
ECM Service Precautions 6E–227. . . . . . . . . . . . . .
Intake Throttle Position (ITP) Sensor 6E–227. . . . .
Transmission Range Switch 6E–227. . . . . . . . . . . . .
Accelerator Position Sensor (AP) 6E–227. . . . . . . .
Aftermarket Electrical and Vacuum
Equipment 6E–227. . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Damage 6E–227. . . . . . . . .
General Description (Air Induction) 6E–228. . . . . . . .
Air Induction System 6E–228. . . . . . . . . . . . . . . . . . .
General Description (Fuel Metering) 6E–228. . . . . . .
Deceleration Mode 6E–228. . . . . . . . . . . . . . . . . . . .
Fuel Injector 6E–228. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Metering System Components 6E–228. . . . . .
A/C Clutch Diagnosis 6E–228. . . . . . . . . . . . . . . . . . . .
A/C Request Signal 6E–228. . . . . . . . . . . . . . . . . . . .
General Description Exhaust Gas
Recirculation (EGR) System 6E–228. . . . . . . . . . . . .
EGR Purpose 6E–228. . . . . . . . . . . . . . . . . . . . . . . . .
Fuse and Relay Panel
(Underhood Electrical Center) RHD 6E–229. . . . . . .
Fuse and Relay Panel
(Underhood Electrical Center) LHD 6E–230. . . . . . .

6E–7 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Specification
Tightening Specifications
Application
NꞏmKgꞏmLb Ft.Lb In.
Camshaft Position Sensor Retaining Screw90.9—78
Crankshaft Position Sensor Mounting Bolt90.9—78
Engine Coolant Temperature Sensor191.914—
Throttle Body Mounting Nuts202.014—
VSS Retaining Bolt161.612—
MAP Sensor Screw40.4—35
EGR VSV Bolts80.8—69
Fuel Temp Sensor191.914—
Oil Temp Sensor Bolt191.914—
Rail Pressure Sensor Bolt202.014—

6E–14
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
ECM Pinouts
ECM Pinout Table, 32-Way Connector – J1 RED – Upper
060RW138
J1 – RED
PINSIGNAL
1FUEL TEMPERATURE
2SPARE ANALOG 1
3+5VB1
4+5VB2
5SPARE ANALOG 3
6ACCEL POS OUT 1
7NOT USED
8SPARE OUT 2 (TCC)
9EVRV (EGR)
10IGN RELAY
11GLOW PLUG LAMP
12DIAGNOSTIC LAMP
13VSV (EXHAUST #2)
14RAIL PRESS CNTRL VALVE
15GLOW PLUG RELAY
16VSV (EXHAUST #1)

6E–19 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Component Locator
Engine Component Locator Table
F06RW051
NumberNameLocation
1AP (Accelerator Pedal Position) SensorAP Bracket
2CKP (Crankshaft Position) SensorInside the right front flywheel Housing
3Oil RailMounted on the camshaft carrier
4Oil (Rail) Pressure SensorMounted on the Oil Rail
5OT (Oil Temperature) SensorMounted on the Oil Rail
6Fuel InjectorIn the Cylinder Head Cover
7Fuel Return OrificeInside the Cylinder Head
8FT (Fuel Temperature) SensorFuel Return Adaptor
9IntercoolerOn the Cylinder Head Cover
10Intake Throttle MotorBehind the Intake Manifold
11Intake ThrottleBehind the Intake Manifold
122 Way Check ValveBelow the Intake Manifold
13VSV (Vacuum Switching Valve)At the left Cylinder Body
14EGR Pressure SensorBelow the Intake Manifold
15Fuel FilterAt the left Engine Room
16CMP (Camshaft Position) SensorOn the forward of Timing Gear Case
17IAT (Intake Air Temperature) SensorBelow the Intake Manifold
18ECT (Engine Coolant Temperature)Thermostat Housing
19High Pressure Oil PumpOn the back Timing Gear Case

6E–20
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
NumberNameLocation
20Rail Pressure Control ValveIn the High Pressure Oil Pump
21Fuel PumpIn the High Pressure Oil Pump
22EVRVOn the Intake Manifold
23MAP (Manifold Absolute Pressure) SensorOn the Intake Manifold
24EGR ValveOn the Intake Manifold
25Air CleanerAt the left Engine Room
26ECMBehind the Air Cleaner