lock OPEL FRONTERA 1998 Workshop Manual

6E–251 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM
T321115
Circuit Description
The powertrain control module (PCM) controls engine
idle speed by adjusting the position of the idle air control
(IAC) motor pintle. The IAC is a bi-directional stepper
motor driven by two coils. The PCM applies current to the
IAC coils in steps (counts) to extend the IAC pintle into a
passage in the throttle body to decrease air flow. The
PCM reverses the current to retract the pintle, increasing
air flow. This method allows highly accurate control of idle
speed and quick response to changes in engine load. If
the PCM detects a condition where too low of an idle
speed is present and the PCM is unable to adjust idle
speed by increasing the IAC counts, DTC P1508 will set,
indicating a problem with the idle control system.
Conditions for Setting the DTC
No Tech 2 test is being run.
None of these DTCs are set: TP sensor, VSS, ECT,
EGR, fuel system, MAF, MAP, IAT, canister purge,
injector control or ignition control.
Barometric pressure is above 75 kPa.
Engine coolant temperature (ECT) is above 50C
(120
F).
Engine speed is more than 100-200 RPM lower than
desired idle, based upon coolant temperature.
The engine has been running for at least 125 seconds.
Vehicle speed is less than 1 mph.
Canister purge duty cycle is above 10%.
Ignition voltage is between 9.5 volts and 16.7 volts.
The throttle is closed.
Engine speed is lower than desired idle.
All of the above conditions are met for 10 seconds.
Action Taken When the DTC Sets
The PCM will illuminate the malfunction indicator lamp
(MIL) after the second consecutive trip in which the
fault is detected.
The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
Failure Records data.
Conditions for Clearing the MIL/DTC
DTC P1508 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids
Check for the following conditions:
Poor connection at PCM or IAC motor – Inspect
harness connectors for backed-out terminals,
improper mating, broken locks, improperly formed or
damaged terminals, and poor terminal-to-wire
connection.
Damaged harness – Inspect the wiring for damage.
Restricted air intake system – Check for a possible
collapsed air intake duct, restricted air filter element,
or foreign objects blocking the air intake system.
Throttle body – Check for objects blocking the IAC
passage or throttle bore, excessive deposits in the IAC

6E–253 ENGINE DRIVEABILITY AND EMISSIONS
DTC P1508 – IAC System Low RPM
StepNo Ye s Va l u e ( s ) Action
5Visually/physically inspect for following conditions:
Restricted air intake system. Check for a possible
collapsed air intake duct, restricted air filter
element, or foreign objects blocking the air intake
system.
T h r o t t l e b o d y. C h e c k f o r o b j e c t s b l o c k i n g t h e I A C
passage or throttle bore, excessive deposits in
the IAC passage and on the IAC pintle, and
excessive deposits in the throttle bore and on the
throttle plate.
Do any of the above require a repair?
—
Refer to
appropriate
section for
on-vehicle
service
Go to Step 6
61. Check for a poor connection at the IAC harness
connector.
2. If a problem is found, replace faulty terminals as
necessary.
Was a problem found?
—Verify repairGo to Step 7
7Replace the IAC valve.
Is the action complete?
—Verify repair—
8Replace the PCM.
IMPORTANT:The replacement PCM must be
programmed. Refer to
UBS 98model year Immobilizer
Workshop Manual.
Is the action complete?—Verify repair—

6E–254
ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1509 IAC System High RPM
T321115
Circuit Description
The powertrain control module (PCM) controls engine
idle speed by adjusting the position of the idle air control
(IAC) motor pintle. The IAC is a bi-directional stepper
motor driven by two coils. The PCM applies current to the
IAC coils in steps (counts) to extend the IAC pintle into a
passage in the throttle body to decrease air flow. The
PCM reverses the current to retract the pintle, increasing
air flow. This method allows highly accurate control of idle
speed and quick response to changes in engine load. If
the PCM detect a condition where too high of an idle
speed is present and the PCM is unable to adjust idle
speed by increasing the IAC counts, DTC P1509 will set,
indicating a problem with the idle control system.
Conditions for Setting the DTC
No Tech 2 test is being run.
None of these DTCs are set: TP sensor, VSS, ECT,
EGR, fuel system, MAF, MAP, IAT, canister purge,
injector control or ignition control.
Barometric pressure is above 75 kPa.
Engine coolant temperature is above 50C (120F).
Engine speed is more than 100-200 RPM lower than
desired idle, based upon coolant temperature.
The engine has been running for at least 125 seconds.
Vehicle speed is less than 1 mph.
Canister purge duty cycle is above 10%.
Ignition voltage is between 9.5 volts and 16.7 volts.
Engine speed is lower than desired idle.
All of the above conditions are met for 5 seconds.
Action Taken When the DTC Sets
The PCM will illuminate the malfunction indicator lamp
(MIL) after the second consecutive trip in which the
fault is detected.
The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
Failure Records data.
Conditions for Clearing the MIL/DTC
DTC P1509 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids
Check for the following conditions:
Poor connection at PCM or IAC motor – Inspect
harness connectors for backed-out terminals,
improper mating, broken locks, improperly formed or
damaged terminals, and poor terminal-to-wire
connection.
Damaged harness – Inspect the wiring for damage.
Vacuum leak – Check for a condition that causes a
vacuum leak, such as disconnected or damaged
h o s e s , l e a k s a t t h e E G R v a l v e a n d t h e E G R p i p e t o t h e
intake manifold, leaks at the throttle body, faulty or
incorrectly installed PCV valve, leaks at the intake
manifold, etc.

6E–258
ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset
Circuit Description
The powertrain control module (PCM) monitors
unexpected PCM reset. This will not turn on MIL light on,
only records code DTC P1625.
Conditions for Setting the DTC
Clock or COP reset.
Action Taken When the DTC Sets
The PCM will not illuminate the malfunction indicator
lamp (MIL).
The PCM will store conditions which were present
when the DTC was set as Failure Records only. This
information will not be stored as Freeze Frame data.
Conditions for Clearing the MIL/DTC
DTC P1625 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids
Check for the following conditions:
P1625 alone stored does not need diagnosis. Clear
DTC code.

6E–259 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1640 Driver-1-Input High Voltage
Circuit Description
Output driver modules (ODMs) are used by the
powertrain control module (PCM) to turn “ON” many of
the current-driven devices that are needed to control
various engine and transmission functions. Each ODM is
capable of controlling up to 7 separate outputs by
applying ground to the device which the PCM is
commanding “ON.”
Unlike the Quad Driver Modules (QDMs) used in prior
model years, ODMs have the capability of diagnosing
each output circuit individually. DTC P1640 set indicates
an improper voltage level has been detected on an ODM
output.
Since A/C is an option, No A/C will cause the air
conditioning clutch relay output to always fault. If a fault is
seen on the air conditioning clutch relay output, it will not
be logged as a fault until the A/C request input interrupts a
high voltage, indicating that A/C has been installed.
Conditions for Setting the DTC
Ignition “ON.”
Engine running.
No DTC 1618.
Ignition voltage is above 13.2 volts for 4 seconds.
Output voltage does not equal ignition voltage when
output is “OFF” or output voltage is not less than 1 volt
when output is “ON.”
Above conditions occur for at least 1 second.
Action Taken When the DTC Sets
The PCM will not illuminate the malfunction indicator
lamp (MIL).
The PCM will store conditions which were present
when the DTC was set as Failure Records only. This
information will not be stored as Freeze Frame data.
Conditions for Clearing the MIL/DTC
DTC P1640 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids
Check for the following conditions:
Poor connection at PCM – Inspect harness connectors
for backed-out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal-to-wire connection.
Damaged harness – Inspect the wiring harness for
damage, If the harness appears to be OK, disconnect
the PCM, turn the ignition “ON” and observe a
voltmeter connected to the suspect driver circuit at the
PCM harness connector while moving connectors and
wiring harnesses relates to the MIL. A change in
voltage will indicate the location of the fault.
Poor connection at component – Examine for
damaged connectors, unplugged connector, or
damaged terminals at the following locations:
Instrument cluster harness, canister purge solenoid,
A/C clutch relay. An open ignition feed circuit at any of
these components will cause DTC P1640 to be set.
Reviewing the Failure Records vehicle mileage since the
diagnostic test last failed may help determine how often
the condition that caused the DTC to be set occurs. This
may assist in diagnosing the condition.
The following PCM pins are controlled by output driver
modules (ODMs):
A13 – “Check Engine Lamp”
A14 – SVS (”Check Trans”)
B14 – A/C Clutch
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
6. The Tech 2 Driver Module Status indicates the PCM
pin that is affected.
11. The Tech 2 may indicate “short circuit” even when
the problem is an open circuit. The cause of an
open circuit may be in the component itself-lamp,
purge, solenoid, or A/C compressor relay.
13.A short to ground on the ignition side of the
component will blow the fuse. Since the fuse was
checked in Step 4, a short to ground would be
between the affected component and the PCM.

6E–273 ENGINE DRIVEABILITY AND EMISSIONS
Rough, Unstable, or Incorrect Idle, Stalling Symptom
StepNo Ye s Va l u e ( s ) Action
101. Visually/physically inspect for the following
conditions:
Restricted air intake system. Check for a
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
Throttle body. Check for objects blocking the
IAC passage or throttle bore, excessive
deposits in the IAC passage and on the IAC
pintle, and excessive deposits in the throttle
bore and on the throttle plate.
Large vacuum leak. Check for a condition that
causes a large vacuum leak, such as an
incorrectly installed or faulty crankcase
ventilation valve or a disconnected brake
booster hose.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 8
11Check the injector connections. If any of the injectors
are connected to an incorrect cylinder, correct as
necessary.
Was a problem found?
—Verify repairGo to Step 12
121. Perform the “Injector Coil/Balance Test” in Fuel
Metering System
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 13
131. Check for fuel in the pressure regulator vacuum
hose.
2. If fuel is present, replace the fuel pressure regulator
assembly. Refer to
Fuel Metering System.
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 14
141. Check for proper ignition voltage output with spark
tester J 26792 (ST-125). Refer to
Electronic Ignition
System
for the procedure.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 15
151. Remove spark plugs. Check for wet plugs, cracks,
wear, improper gap, burned electrodes, or heavy
deposits. Refer to
Electronic Ignition System.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 16
161. Check for a loose ignition coil ground.
Refer to
Electrical Ignition System.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 17

6E–283 ENGINE DRIVEABILITY AND EMISSIONS
Cuts Out, Misses Symptom
StepNo Ye s Va l u e ( s ) Action
101. Visually/physically inspect for the following
conditions:
Restricted air intake system. Check for a
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
Throttle body. Check for objects blocking the
IAC passage or throttle bore, excessive
deposits in the IAC passage and on the IAC
pintle, and excessive deposits in the throttle
bore and on the throttle plate.
Large vacuum leak. Check for a condition that
causes a large vacuum leak, such as an
incorrectly installed or faulty PCV valve or
brake booster hose disconnected .
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 8
11Check the injector connections. If any of the injectors
are connected to an incorrect cylinder, correct as
necessary.
Was a problem found?
—Verify repairGo to Step 12
121. Perform the “Injector Coil/Balance Test” in Fuel
Metering System
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 13
131. Check for fuel in the pressure regulator vacuum
hose.
2. If fuel is present, replace the fuel pressure regulator
assembly. Refer to
Fuel Metering System.
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 14
141. Check for proper ignition voltage output with spark
tester J 26792 (ST-125). Refer to
Electronic Ignition
System
for the procedure.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 15
151. Remove spark plugs. Check for wet plugs, cracks,
wear, improper gap, burned electrodes, or heavy
deposits. Refer to
Electronic Ignition System.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 16
161. Check for a loose ignition coil ground.
Refer to
Electronic Ignition System.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 17

6E–292
ENGINE DRIVEABILITY AND EMISSIONS
Crankshaft Position (CKP)
Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector to the CKP
sensor.
3. Remove one bolt and the CKP sensor from the right
side of the engine block, just behind the mount.
NOTE: Use caution to avoid any hot oil that might drip
out.
TS22909
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.).
TS22909
3. Connect the electrical connector to the CKP sensor.
4. Connect the negative battery cable.
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.
014RW127

6E–296
ENGINE DRIVEABILITY AND EMISSIONS
Knock Sensor (KS)
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the cooling system. Refer to
Draining and
Filling the Cooling System
in Engine Cooling.
3. Remove the engine cover.
4. Remove the common chamber assembly.
Refer to Common Chamber in Engine Mechanical.
014RW106
5. Disconnect the electrical connector from the knock
sensor.
014RW103
6. Unscrew the knock sensor from the engine block.
Installation Procedure
NOTE: Do not apply thread sealant to the sensor threads.
The sensor is coated at the factory and applying
additional sealant will affect the sensor’s ability to detect
detonation.
1. Screw the knock sensor into the engine block.
Tighten
Tighten the knock sensor to 20 Nꞏm (177 lb in.).
014RW103
2. Connect the electrical connector to the knock sensor.
3. Install the common chamber assembly.
Refer to Common Chamber in Engine Mechanical.
014RW106
4. Install the engine cover.
5. Fill the cooling system.
Refer to Draining and Filling the Cooling System in
Engine Cooling.
6. Connect the negative battery cable.

6E–299 ENGINE DRIVEABILITY AND EMISSIONS
damage, therefore, it is important to use care when
handling and testing electronic components.
NOTE: To prevent possible Electrostatic Discharge
damage, follow these guidelines:
Do not touch the control module connector pins or
soldered components on the control module circuit
board.
Do not open the replacement part package until the
part is ready to be installed.
Before removing the part from the package, ground
the package to a known good ground on the vehicle.
If the part has been handled while sliding across the
seat, or while sitting down from a standing position, or
while walking a distance, touch a known good ground
before installing the part.
NOTE: To prevent internal PCM damage, the ignition
must be in the “OFF” position in order to disconnect or
reconnect power to the PCM (for example: battery cable,
PCM pigtail, PCM fuse, jumper cables, etc.).
IMPORTANT:When replacing the production PCM
with a service PCM, it is important to transfer the
broadcast code and production PCM number to the
service PCM label. This will allow positive identification of
PCM parts throughout the service life of the vehicle. Do
not record this information on the metal PCM cover.
IMPORTANT:The ignition should always be in the
“OFF” position in order to install or remove the PCM
connectors.
Service of the PCM should normally consist of either re-
placement of the PCM or EEPROM programming. If the
diagnostic procedures call for the PCM to be replaced,
the PCM should be checked first to ensure it is the correct
part. If it is, remove the faulty PCM and install the new
service PCM.
The service PCM EEPROM will not be programmed.
DTC P0601 indicates the check sum error.
Removal Procedure
1. Disconnect the negative battery cable.
2. Block the wheels.
3. Remove the front console assembly.
1. Remove the four screws.
TS23755
2. Remove the transfer shift lever knob by
unscrewing the knob.
3. Move the transmission gear selector out of the
park position.
4. Lift up sharply on the back edge of the assembly.
5. Disconnect the seat heater switch connectors (if
equipped).
6. Disconnect the POWER and WINTER switch
connectors.
7. Lift out the front console assembly.
TS23756