brake OPEL FRONTERA 1998 Workshop Manual

6E–15 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
ECM Pinout Table, 32-Way Connector – J1 RED – Lower
060RW137
J1 – RED
PINSIGNAL
17SPARE ANALOG 4
18INTAKE SM POSITION
19VEHICLE SPEED
20MT NEUTRAL
21REVERSE SW
22ACCEL POS OUT 2
23THERMO SW RELAY
24SPARE OUT 3 (TURBO)
25VSV (EGR)
26TACHOMETER 1
27BRAKE SW 1
28NOT USED (BRAKE 2)
29A/T NEUTRAL SW
30NO CONNECTION
31AC REQUEST SW
32AT SOLENOID

6E–26
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Output Components:
Output components are diagnosed for proper response to
control module commands. Components where
functional monitoring is not feasible will be monitored for
circuit continuity and out-of-range values if applicable.
Output components to be monitored include, but are not
limited to, the following circuit:
EGR VSV
EGR EVRV
Electronic Transmission controls
Injector
Intake throttle
Glow plug
MIL control
Refer to ECM and Sensors in General Descriptions.
Passive and Active Diagnostic Tests
A passive test is a diagnostic test which simply monitors a
vehicle system or component. Conversely, an active test,
actually takes some sort of action when performing
diagnostic functions, often in response to a failed passive
test.
Intrusive Diagnostic Tests
This is any on-board test run by the Diagnostic
Management System which may have an effect on
vehicle performance or emission levels.
Warm-Up Cycle
A warm-up cycle means that engine at temperature must
reach a minimum of 70
C (160F) and rise at least 22C
(40
F) over the course of a trip.
Freeze Frame
Freeze Frame is an element of the Diagnostic
Management System which stores various vehicle
information at the moment an emissions-related fault is
stored in memory and when the MIL is commanded on.
These data can help to identify the cause of a fault. Refer
to
Storing And Erasing Freeze Fame Data for more
detailed information.
Failure Records
Failure Records data is an enhancement of the OBD
Freeze Frame feature. Failure Records store the same
vehicle information as does Freeze Frame, but it will store
that information for any fault which is stored in on-board
memory, while Freeze Frame stores information only for
emission-related faults that command the MIL on.
Common OBD Terms
Diagnostic
When used as a noun, the word diagnostic refers to any
on-board test run by the vehicle’s Diagnostic
Management System. A diagnostic is simply a test run on
a system or component to determine if the system or
component is operating according to specification. There
are many diagnostics, shown in the following list:
EGR
engine speed
vehicle speed
ECT
MAP
VSV
IAT
ITP
AP
FT (Fuel Temp)
RP (Rail Pressure)
OT (Oil Temp)
EGR EVRV
Idle SW
Brake SW
The Diagnostic Executive
The Diagnostic Executive is a unique segment of
software which is designed to coordinate and prioritize
the diagnostic procedures as well as define the protocol
for recording and displaying their results. The main
responsibilities of the Diagnostic Executive are listed as
follows:
Commanding the MIL (“Check Engine” lamp) on and
off
DTC logging and clearing
Freeze Frame data for the first emission related DTC
recorded
Current status information on each diagnostic
Diagnostic Information
The diagnostic charts and functional checks are designed
to locate a faulty circuit or component through a process
of logical decisions. The charts are prepared with the
requirement that the vehicle functioned correctly at the
time of assembly and that there are not multiple faults
present.
There is a continuous self-diagnosis on certain control
functions. This diagnostic capability is complemented by
the diagnostic procedures contained in this manual. The
language of communicating the source of the malfunction
is a system of diagnostic trouble codes. When a
malfunction is detected by the control module, a
diagnostic trouble code is set and the Malfunction
Indicator Lamp (MIL) (“Check Engine” lamp) is
illuminated.
Malfunction Indicator Lamp (MIL)
The Malfunction Indicator Lamp (MIL) looks the same as
the MIL you are already familiar with “Check Engine”
lamp.
Basically, the MIL is turned on when the ECM detects a
DTC that will impact the vehicle emissions.
When the MIL remains “ON” while the engine is
running, or when a malfunction is suspected due to a
driveability or emissions problem, a Powertrain
On-Board Diagnostic (OBD) System Check must be
performed. The procedures for these checks are
given in On-Board Diagnostic (OBD) System Check.
These checks will expose faults which may not be
detected if other diagnostics are performed first.
DTC Types
Characteristic of Code

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.

6E–42
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
4JX1-TC Engine (Automatic and Manual Transmission)
Te c h 2
Parameter
Data ListUnits
DisplayedTy p i c a l D a t a
Values (IDLE)Typical Data
Va l u e s
(2500 RPM)Refer To
Battery VoltageEngineVo l t s12.5 14.513 15General Description
Ignition StatusEngineOn/OffOnOnGeneral Description
Ignition Relay2EngineOn/OffOnOnGeneral Description
Idle SwitchEngineInactive/
Active——DTC P0510, P1510
Manifold
Absolute
PressureEngineKPa96 106110 150General Description
DTC P0107, P0108
Rail Oil
PressureEngineMPa3.5 54.5 10General Description
DTC P0192, P0193
Desired Rail Oil
PressureEngineMPa4 55 9General Description
DTC P0192, P0193
Fuel
TemperatureEngineC (F)75 8575 85DTC P0182, P0183
Quick Warming
SwitchEngineOn/OffOffOffDTC P0380
Thermo RelayEngineOn/Off——DTC P1655
Actual EGR
PressureEngineKPa58 60M/T 63 66
A/T 95
105
DTC P0405, P0406
Barometric
PressureEngineKPa98 10298 102General Description
Relative EGR
PressureEngineKPa–38 –45M/T –34 –37
A/T 0General Description
Desired EGR
PressureEngineKPa–43 –40M/T 36
A/T 0General Description
Brake SwitchEngineInactive/
Active——DTC P1588
GearEngine————
Vehicle SpeedEngineKm/h00Transmission Diagnosis
Rail Pressure
Control ValveEngine%17 2218 27DTC P1193
EGR StatusEngineDisable/
EnableEnableM/T Enable
A/T DisableGeneral Description
EGR Switching
Va l v eEngineOn/Off——General Description
Throttle Motor
Position SensorEngineVo l t s3.1 3.90.2 0.9DTC P1485, P1486,
P1487
Throttle Motor
PositionEngineSteps
0 1.00 1.0
DTC P1488
Delirered Fuel
QuantityEnginemm 3/st
6 106 12
General Description
Injector StatusEngineDisable/
EnableEnableEnableDTC P0201, P0202,
P0203, P0204, General
Description
Injector Pulse
WidthEnginems0.9 1.250.7 1.1General Description
Injector Start
OffsetEngineCA——General Description

6E–55 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
DTC
using a
Te c h 2Flash DTCDescriptionMIL
P047571EXH #1 VSV Circuit Open/Short—
P147571EXH #2 VSV Circuit Open/Short—
P148574Intake Throttle Position Sensor Low VoltageON
P148674Intake Throttle Position Sensor High VoltageON
P148773Intake Throttle System Circuit Open/ShortON
P148872Intake Throttle Motor Control Circuit Signal Gap—
P050224Vehicle Speed Sensor No SignalON
P051075Idle SW Malfunction, Open CircuitON
P151075Idle SW Malfunction, Short CircuitON
P056235System Voltage Too LowON
P156235System Voltage Too Low at CrankingON
P158725Brake SW Malfunction [B]—
P158825Brake SW Malfunction [A]ON
P060155ECM Checksum ErrorON
P162656Immobilizer No SignalON
P163156Immobilizer Wrong SignalON
P164856No Security Code EnteredON
P164956Immobilizer Function not ProgrammedON
P065077Check Engine Lamp Circuit Open/Short—
P065427Techometer Circuit Open/Short—
P165517Thermo Relay Circuit Open/Short—
P165776ECM Main Relay Circuit Open/Short—
P158947TransMission SW Circuit Open/Short—

6E–161 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1587 (Flash DTC 25)
Brake SW Malfunction
060RW130
Circuit Description
Brake Stop Lamp SW Circuit receives through Stop Lamp
10A fuse from the battery.
Action Taken When the DTC Sets
The ECM 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 P1587 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the ECM battery
feed.
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM – 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, observe the
Brake SW display on the Tech 2 while moving
connectors and wiring harnesses related to the Brake
SW. A change in the display will indicate the location
of the fault.
If DTC P1587 cannot be duplicated, the information
included in the Failure Records data can be useful in
determining vehicle mileage since the DTC was last set.

6E–162
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
DTC P1587 – Brake SW Malfunction
StepActionVa l u e ( s )Ye sNo
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2
Go to OBD
System
Check
21. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor the “DTC” info for DTC
P1587.
Does the Tech 2 indicate DTC P1587 failed?
—Go to Step 3
Refer to
Diagnostic
Aids
3Check the Brake SW circuit for a poor connection and
replace the terminal if necessary.
Did the terminal require replacement?
—Verify repairGo to Step 4
4Replace the Brake SW.
Is the action complete?
—Verify repair—

6E–163 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1588 (Flash DTC 25)
Brake SW Malfunction
060RW130
Circuit Description
Brake Stop Lamp SW Circuit receives through Stop Lamp
10A fuse from the battery.
Action Taken When the DTC Sets
The ECM will illuminate the malfunction indicator lamp
(MIL) the first time the fault is detected.
The ECM 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 P1588 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the ECM battery
feed.
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM – 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, observe the
Brake SW display on the Tech 2 while moving
connectors and wiring harnesses related to the Brake
SW. A change in the display will indicate the location
of the fault.
If DTC P1588 cannot be duplicated, the information
included in the Failure Records data can be useful in
determining vehicle mileage since the DTC was last set.

6E–164
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
DTC P1588 – Brake SW Malfunction
StepActionVa l u e ( s )Ye sNo
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2
Go to OBD
System
Check
21. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor the “DTC” info for DTC
P1588.
Does the Tech 2 indicate DTC P1588 failed?
—Go to Step 3
Refer to
Diagnostic
Aids
3Check the Brake SW circuit for a poor connection and
replace the terminal if necessary.
Did the terminal require replacement?
—Verify repairGo to Step 4
4Replace the Brake SW.
Is the action complete?
—Verify repair—

6E–189 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Cuts Out, Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Steady pulsation or jerking that follows engine speed;
usually more pronounced as engine load increases.
Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2
Go to OBD
System
Check
21. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?
—Go to Step 7Go to Step 3
3Was a visual/physical check performed?
—Go to Step 4
Go to Visual/
Physical
Check
41. Check the ECM grounds for clearness, tightness
and proper routing. Refer to the ECM wiring
diagrams in
Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 5
51. Check for incorrect idle speed. Ensure that the
following conditions are present:
The engine is fully warm.
The accessories are “off.”
2. Using a Tech 2, monitor the AP position.
Is the AP position within the specified values?
0%Go to Step 6Go to Step 7
61. 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.
Check the Throttle body.
Large vacuum leak. Check for a condition that
causes a large vacuum leak, such as an
incorrectly installed or faulty VSV or brake
booster hose disconnected .
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
7Using a Tech 2, monitor the AP angle with the engine
idling.
Is the AP angle at the specified value and steady?
0%Go to Step 8
Refer to DTC
P0123
for
further
diagnosis
81. Check the transmission range switch circuit. Use a
Tech 2 and be sure the Tech 2 indicates that the
vehicle is in drive with the gear selector in drive or
overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary.
Was a problem found?
—Verify repairGo to Step 9