service OPEL FRONTERA 1998 Workshop Manual

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.
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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.).
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3. Connect the electrical connector to the CMP sensor.
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4. Connect the negative battery cable.

6E–206
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
3. Disconnect the electrical connector from the OT
sensor.
4. Remove the OT sensor.
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Installation Procedure
1. Install the OT sensor.
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2. Connect the OT sensor electrical connector.
3. Install the battery.
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4. Connect the negative battery cable.
Malfunction Indicator Lamp
(MIL)
Removal and Installation Procedure
Refer to Meter in Electrical section.
Engine Control Module (ECM)
Service Precaution
NOTE: To prevent possible electrostatic discharge
damage to the ECM, do not touch the connector pins or
soldered components on the circuit board.
When replacing the ECM to prevent possible electro
damage, follow these guidelines:
Before removing the ECM, disconnect the negative
battery cable.
Before install the ECM, install the negative battery cable.
Electrostatic Discharge (ESD)
Damage
Electronic components used in the control systems are
often designed to carry very low voltage. Electronic
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static
electricity can cause damage to some electronic
components. By comparison, it takes as much as 4,000
volts for a person to even feel the zap of a static
discharge.
There are several ways for a person to become statically
charged. The most common methods of charging are by
friction and by induction. An example of charging by
friction is a person sliding across a car seat.
Charging by induction occurs when a person with well
insulated shoes stands near a highly charged object and
momentarily touches ground. Charges of the same
polarity are drained off leaving the person highly charged
with the opposite polarity. Static charges can cause

6E–207 4JX1–TC 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 ECM damage, the ignition
must be in the “OFF” position in order to disconnect or
reconnect power to the ECM (for example: battery cable,
ECM pigtail, ECM fuse, jumper cables, etc.).
IMPORTANT:When replacing the production ECM
with a service ECM, it is important to transfer the
broadcast code and production ECM number to the
service ECM label. This will allow positive identification of
ECM parts throughout the service life of the vehicle. Do
not record this information on the metal ECM cover.
IMPORTANT:The ignition should always be in the
“OFF” position in order to install or remove the ECM
connectors.
Service of the ECM should normally consist of either re-
placement of the ECM. If the diagnostic procedures call
for the ECM to be replaced, the ECM should be checked
first to ensure it is the correct part. If it is, remove the
faulty ECM and install the new service ECM.
DTC P0601 indicates the check sum error.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the ECM connector.
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3. Remove the bolts ECM bracket and battery bracket.
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4. Remove the ECM.
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6E–220
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Install the EVRV.
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2. Connect the EVRV hose and the EVRV connector.
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3. Connect the negative battery cable.
Wiring and Connectors
Wiring Harness Service
The ECM harness electrically connects the ECM to the
various solenoids, switches and sensors in the vehicle
engine compartment and passenger compartment.
Replace wire harnesses with the proper part number
replacement.
Because of the low amperage and voltage levels utilized
in powertrain control systems, it is essential that all wiring
in environmentally exposed areas be repaired with crimp
and seal splice sleeves.The following wire harness repair information is intended
as a general guideline only. Refer to
Chassis Electrical f o r
all wire harness repair procedures.
Connectors and Terminals
Use care when probing a connector and when replacing
terminals. It is possible to short between opposite
terminals. Damage to components could result. Always
use jumper wires between connectors for circuit
checking. NEVER probe through Weather-Pack seals.
Use an appropriate connector test adapter kit which
contains an assortment of flexible connectors used to
probe terminals during diagnosis. Use an appropriate
fuse remover and test tool for removing a fuse and to
adapt the fuse holder to a meter for diagnosis.
Open circuits are often difficult to locate by sight because
oxidation or terminal misalignment are hidden by the
connectors. Merely wiggling a connector on a sensor, or
in the wiring harness, may temporarily correct the open
circuit. Intermittent problems may also be caused by
oxidized or loose connections.
Be certain of the type of connector/terminal before
making any connector or terminal repair. Weather-Pack
and Com-Pack III terminals look similar, but are serviced
differently.
Wire Harness Repair: Twisted
Shielded Cable
Removal Procedure
1. Remove the outer jacket.
2. Unwrap the aluminum/mylar tape. Do not remove the
mylar.
047

6E–226
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
0018
Manifold Absolute Pressure (MAP) Sensor
The manifold absolute pressure (MAP) sensor responds
to changes in intake manifold pressure. The MAP sensor
signal voltage to the ECM varies from below 2 volts at idle
(high vacuum) to above 4 volts.
The MAP sensor is used to determine the following:
Boost pressure for injector control.
Barometric pressure (BARO).
If the ECM detects a voltage that is lower than the
possible range of the MAP sensor, DTC P0107 will be set.
A signal voltage higher than the possible range of the
sensor will set DTC P0108. An intermittent low or high
voltage will set DTC P1107 or DTC P1106, respectively.
The ECM can detect a shifted MAP sensor. The ECM
compares the MAP sensor signal to a calculated MAP
based on throttle position and various engine load factors.
If the ECM detects a MAP signal that varies excessively
above or below the calculated value, DTC P0106 will set.
Engine Control Module (ECM)
The engine control module (ECM) is located in the engine
room.
The ECM constantly observes the information from
various sensors. The ECM controls the systems that
affect vehicle performance. The ECM performs the
diagnostic function of the system. It can recognize
operational problems, alert the driver through the MIL
(Service Engine Soon lamp), and store diagnostic trouble
codes (DTCs). DTCs identify the problem areas to aid the
technician in making repairs.
ECM Function
The ECM supplies 5, 12 and 110 volts to power various
sensors or switches. The power is supplied through
resistances in the ECM which are so high in value that a
test light will not light when connected to the circuit. In
some cases, even an ordinary shop voltmeter will not give
an accurate reading because its resistance is too low.
Therefore, a digital voltmeter with at least 10 megohms
input impedance is required to ensure accurate voltage
readings. The ECM controls output circuits such as theinjectors, glow relays, etc., by controlling the ground or
the power feed circuit through transistors or through
either of the following two devices:
Output Driver Module (ODM)
Quad Driver Module (QDM)
ECM Components
The ECM is designed to maintain exhaust emission levels
to government mandated standards while providing
excellent driveability and fuel efficiency. The ECM
monitors numerous engine and vehicle functions via
electronic sensors such as the crankshaft position (CKP)
sensor, and vehicle speed sensor (VSS). The ECM also
controls certain engine operations through the following:
Fuel injector control
Rail pressure control
ECM Voltage Description
The ECM supplies a buffered voltage to various switches
and sensors. It can do this because resistance in the
ECM is so high in value that a test light may not illuminate
when connected to the circuit. An ordinary shop
voltmeter may not give an accurate reading because the
voltmeter input impedance is too low. Use a 10-megohm
input impedance digital voltmeter to assure accurate
voltage readings.
The input/output devices in the ECM include
analog-to-digital converters, signal buffers, counters,
and special drivers. The ECM controls most components
with electronic switches which complete a ground circuit
when turned “ON.” These switches are arranged in
groups of 4 and 7, called either a surface-mounted quad
driver module (QDM), which can independently control up
to 4 output terminals, or QDMs which can independently
control up to 7 outputs. Not all outputs are always used.
ECM Input/Outputs
Inputs – Operating Conditions Read
Air Conditioning “ON” or “OFF”
Engine Coolant Temperature
Crankshaft Position
Electronic Ignition
Manifold Absolute Pressure
Battery Voltage
Intake Throttle Position
Vehicle Speed
Fuel Temperature
Oil Temperature
Intake Air Temperature
EGR boost pressure
Oil rail pressure
Camshaft Position
Accelerator position
Outputs – Systems Controlled
Exhaust Gas Recirculation (EGR)
Injector Control
QWS

6E–227 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
QOS
Diagnostics
– Malfunction Indicator Lamp (Service Engine
Soon lamp)
– Data Link Connector (DLC)
– Data Output
ECM Service Precautions
The ECM is designed to withstand normal current draws
associated with vehicle operation. Avoid overloading any
circuit. When testing for opens and shorts, do not ground
or apply voltage to any of the ECM’s circuits unless
instructed to do so. These circuits should only be tested
using digital voltmeter. The ECM should remain
connected to the ECM or to a recommended breakout
box.
Intake Throttle Position (ITP) Sensor
ITP sensor is a potentiometer type and installed to the
intake throttle valve body. A voltage of 5V is applied
constantly from ECM to ITP sensor thereby to determine
by change in voltage the opening of the intake throttle
valve during warming up.
Transmission Range Switch
IMPORTANT:The vehicle should not be driven with the
transmission range switch disconnected; idle quality will
be affected.
The four inputs from the transmission range switch
indicate to the ECM which position is selected by the
transmission selector lever.
For more information on the transmission on the
transmission range switch, refer to
Automatic
Tr a n s m i s s i o n
.
Accelerator Position Sensor (AP)
AP sensor is a potentiometer type and installed to
accelerator pedal bracket. A voltage of 5V constantly
applied from ECM to the sensor thereby to determine the
accelerator pedaling angle by change in voltage. Further,
this sensor is provided with an accelerator switch, which
is set off only when the accelerator pedal is stepped on.
Aftermarket Electrical and Vacuum
Equipment
Aftermarket (add-on) electrical and vacuum equipment is
defined as any equipment which connects to the vehicle’s
electrical or vacuum systems that is installed on a vehicle
after it leaves the factory. No allowances have been
made in the vehicle design for this type of equipment.
NOTE: No add-on vacuum equipment should be added
to this vehicle.
NOTE: Add-on electrical equipment must only be
connected to the vehicle’s electrical system at the battery
(power and ground).
Add-on electrical equipment, even when installed to
these guidelines, may still cause the powertrain system to
malfunction. This may also include equipment not
connected to the vehicle electrical system such asportable telephones and radios. Therefore, the first step
in diagnosing any powertrain problem is to eliminate all
aftermarket electrical equipment from the vehicle. After
this is done, if the problem still exists, it may be diagnosed
in the normal manner.
Electrostatic Discharge Damage
Electronic components used in the ECM are often
designed to carry very low voltage. Electronic
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static
electricity can cause damage to some electronic
components. By comparison, it takes as much as 4000
volts for a person to feel even the zap of a static
discharge.
TS23793
There are several ways for a person to become statically
charged. The most common methods of charging are by
friction and induction.
An example of charging by friction is a person sliding
across a vehicle seat.
Charge by induction occurs when a person with well
insulated shoes stands near a highly charged object
and momentary touches ground. Charges of the
same polarity are drained off leaving the person
highly charged with the opposite polarity. Static
charges can cause 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 ECM connector pins or soldered
components on the ECM 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, while sitting down from a standing position, or
while walking a distance, touch a known good ground
before installing the part.

ENGINE EXHAUST 6F – 1
ENGINE EXHAUST
CONTENTS
CAUTION: Exhaust system components must have
enough clearance from the underbody to prevent
overheating of the floor pan and possible damage to the passenger compartment, insulation and trim
materials.
General Description . . . . . . . . . . . . . . . . . . 6F–2
Hangers . . . . . . . . . . . . . . . . . . . . . . . . . 6F–2
Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 6F–3
Front Exhaust Pipe . . . . . . . . . . . . . . . . . 6F–3Center Exhaust Pipe . . . . . . . . . . . . . . . . 6F–5
Exhaust Silencer . . . . . . . . . . . . . . . . . . . 6F–6
Rear Exhaust Pipe . . . . . . . . . . . . . . . . . 6F–7

ENGINE EXHAUST 6F – 3
ON-VEHICLE SERVICE
FRONT EXHAUST PIPE
Rattles and noise vibrations in the exhaust system are
usually caused by misalignment of parts. When aligning
the system, leave all bolts or nuts loose until all parts
are properly aligned; then tighten, working from front to
rear.
1. Check connections for looseness or damage,
especially for exhaust gas leakage.
2. Check clamps and rubbers for weakness, cracks or
damage.3. If any part of the converter heat shield is damaged
or dented to the extent that it contacts the catalyst,
repair or replace.
4. Check for dents or damage and for any holes or
cracks caused by corrosion.
3
2 1
Legend
(1) Front exhaust pipe
(2) Center exhaust pipe
(3) Mounting rubber
150RW071

INDUCTION 6J – 5
INSPECTION AND REPAIR
Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is
discovered during inspection.
Minor servicing operations are described in this section.
Contact the nearest IHI SERVICE FACILITY for major
repairs and maintenance.
Refer to IHI SERVICE NETWORK at the end of this
section for the location of your area’s IHI SERVICE
FACILITY.
Turbine shaft end play.
1) Set a dial indicator to the turbine shaft end.
2) Apply a force of 11.8 N (1.2 kg / 2.6 lb)
alternately to the compressor wheel and and the
turbine wheel end.
3) Read the dial indicator.
Turbine End Play
Standard: 0.03 – 0.06 mm (0.0012 – 0.0024 in)
Limit: 0.09 mm (0.0035 in)Turbine shaft and bearing clearance
1) Set a dial indicator to the turbine shaft center
through the center housing oil drain port.
2) Move the turbine shaft from side to side.
3 Read the dial indicator.
Turbine Shaft and Bearing Clearance
Standard: 0.056 - 0.127 mm (0.0022 - 0.0050 in)
Limit: 0.14 mm (0.0055 in)
Waste gate operation
1) Remove hose from waste gate actuator side and
install pressure gauge (1) to the waste gate
actuator.
2) Operate pump of pressure gauge while engine is
stopped.
3) Read pressure at the control rod (2) move 2mm.
Pressure: 106 – 115 kPa
(796 – 862 mmHg/ 15.4 – 16.7 PSi)
036RW008
036RW010
036RW009
036RW007