OPEL FRONTERA 1998 Workshop Manual

6E–34
ENGINE DRIVEABILITY AND EMISSIONS
Sensors and Miscellaneous Component
Locators
For EC.
060RW194
For AUSTRALIA, THAILAND, SOUTH EAST ASIA,
LATIN AMERICA, GULF, SAUDI, CHINA.
150RW101
T321066
T321067

6E–35 ENGINE DRIVEABILITY AND EMISSIONS
140RW032
014RW125
T321070
055RW003
041RW004
025RW005

6E–36
ENGINE DRIVEABILITY AND EMISSIONS
T321078
060RW007
028RW001

6E–37 ENGINE DRIVEABILITY AND EMISSIONS
Diagnosis
Strategy-Based Diagnostics
Strategy-Based Diagnostics
The strategy-based diagnostic is a uniform approach to
repair all Electrical/Electronic (E/E) systems. The
diagnostic flow can always be used to resolve an E/E
system problem and is a starting point when repairs are
necessary. The following steps will instruct the technician
how to proceed with a diagnosis:
1. Verify the customer complaint.
To verify the customer complaint, the technician
should know the normal operation of the system.
2. Perform preliminary checks.
Conduct a thorough visual inspection.
Review the service history.
Detect unusual sounds or odors.
Gather diagnostic trouble code information to
achieve an effective repair.
3. Check bulletins and other service information.
This includes videos, newsletters, etc.
4. Refer to service information (manual) system
check(s).
“System checks” contain information on a system
that may not be supported by one or more DTCs.
System checks verify proper operation of the
system. This will lead the technician in an
organized approach to diagnostics.
5. Refer to service diagnostics.
DTC Stored
Follow the designated DTC chart exactly to make an
effective repair.
No DTC
Select the symptom from the symptom tables. Follow the
diagnostic paths or suggestions to complete the repair.
You may refer to the applicable component/system check
in the system checks.
No Matching Symptom
1. Analyze the complaint.
2. Develop a plan for diagnostics.
3. Utilize the wiring diagrams and the theory of
operation.
Call technical assistance for similar cases where repair
history may be available. Combine technician knowledge
with efficient use of the available service information.
Intermittents
Conditions that are not always present are called
intermittents. To resolve intermittents, perform the
following steps:
1. Observe history DTCs, DTC modes, and freezeframe
data.
2. Evaluate the symptoms and the conditions described
by the customer.3. Use a check sheet or other method to identify the
circuit or electrical system component.
4. Follow the suggestions for intermittent diagnosis
found in the service documentation.
Most Tech 2s, such as the Tech II and the
5–8840–0285–0 (Fluke model 87 DVOM), have
data-capturing capabilities that can assist in detecting
intermittents.
No Trouble Found
This condition exists when the vehicle is found to operate
normally. The condition described by the customer may
be normal. Verify the customer complaint against another
vehicle that is operating normally. The condition may be
intermittent. Verify the complaint under the conditions
described by the customer before releasing the vehicle.
1. Re-examine the complaint.
When the Complaint cannot be successfully found or
isolated, a re-evaluation is necessary. The complaint
should be re-verified and could be intermittent as
defined in
Intermittents, or could be normal.
2. Repair and verify.
After isolating the cause, the repairs should be made.
Validate for proper operation and verify that the
symptom has been corrected. This may involve road
testing or other methods to verify that the complaint
has been resolved under the following conditions:
Conditions noted by the customer.
If a DTC was diagnosed, verify a repair by
duplicating conditions present when the DTC was
set as noted in the Failure Records or Freeze
Frame data.
Verifying Vehicle Repair
Verification of the vehicle repair will be more
comprehensive for vehicles with OBD system
diagnostics. Following a repair, the technician should
perform the following steps:
IMPORTANT:Follow the steps below when you verify
repairs on OBD systems. Failure to follow these steps
could result in unnecessary repairs.
1. Review and record the Failure Records and the
Freeze Frame data for the DTC which has been
diagnosed (Freeze Frame data will only be stored for
an A or B type diagnostic and only if the MIL(”Check
Engine” lamp) has been requested).
2. Clear the DTC(S).
3. Operate the vehicle within conditions noted in the
Failure Records and Freeze Frame data.
4. Monitor the DTC status information for the specific
DTC which has been diagnosed until the diagnostic
test associated with that DTC runs.

6E–38
ENGINE DRIVEABILITY AND EMISSIONS
General Service Information
OBD Serviceablity Issues
The list of non-vehicle faults that could affect the
performance of the OBD system has been compiled.
These non-vehicle faults vary from environmental
conditions to the quality of fuel used.
The illumination of the MIL (“Check Engine” lamp) due to
a non-vehicle fault could lead to misdiagnosis of the
vehicle, increased warranty expense and customer
dissatisfaction. The following list of non-vehicle faults
does not include every possible fault and may not apply
equally to all product lines.
Fuel Quality
Using fuel with the wrong octane rating for your vehicle
may cause driveability problems. Many of the major fuel
companies advertise that using “premium” gasoline will
improve the performance of your vehicle. Most premium
fuels use alcohol to increase the octane rating of the fuel.
Although alcohol-enhanced fuels may raise the octane
rating, the fuel’s ability to turn into vapor in cold
temperatures deteriorates. This may affect the starting
ability and cold driveability of the engine.
Low fuel levels can lead to fuel starvation, lean engine
operation, and eventually engine misfire.
Non-OEM Parts
All of the OBD diagnostics have been calibrated to run
with OEM parts. Something as simple as a
high-performance exhaust system that affects exhaust
system back pressure could potentially interfere with the
operation of the EGR valve and thereby turn on the MIL
(“Check Engine” lamp). Small leaks in the exhaust
system near the post catalyst oxygen sensor can also
cause the MIL (“Check Engine” lamp) to turn on.
Aftermarket electronics, such as cellular phones,
stereos, and anti-theft devices, may radiate EMI into the
control system if they are improperly installed. This may
cause a false sensor reading and turn on the MIL (“Check
Engine” lamp).
Environment
Temporary environmental conditions, such as localized
flooding, will have an effect on the vehicle ignition system.
If the ignition system is rain-soaked, it can temporarily
cause engine misfire and turn on the MIL (“Check Engine”
lamp).
Poor Vehicle Maintenance
The sensitivity of OBD diagnostics will cause the MIL
(“Check Engine” lamp) to turn on if the vehicle is not
maintained properly. Restricted air filters, fuel filters, and
crankcase deposits due to lack of oil changes or improper
oil viscosity can trigger actual vehicle faults that were not
previously monitored prior to OBD. Poor vehicle
maintenance can not be classified as a “non-vehicle
fault”, but with the sensitivity of OBD diagnostics, vehicle
maintenance schedules must be more closely followed.Related System Faults
Many of the OBD system diagnostics will not run if the
PCM detects a fault on a related system or component.
One example would be that if the PCM detected a Misfire
fault, the diagnostics on the catalytic converter would be
suspended until Misfire fault was repaired. If the Misfire
fault was severe enough, the catalytic converter could be
damaged due to overheating and would never set a
Catalyst DTC until the Misfire fault was repaired and the
Catalyst diagnostic was allowed to run to completion. If
this happens, the customer may have to make two trips to
the dealership in order to repair the vehicle.
Maintenance Schedule
Refer to the Maintenance Schedule.
Visual / Physical Engine Compartment
Inspection
Perform a careful visual and physical engine
compartment inspection when performing any diagnostic
procedure or diagnosing the cause of an emission test
failure. This can often lead to repairing a problem without
further steps. Use the following guidelines when
performing a visual/physical inspection:
Inspect all vacuum hoses for punches, cuts,
disconnects, and correct routing.
Inspect hoses that are difficult to see behind other
components.
Inspect all wires in the engine compartment for proper
connections, burned or chafed spots, pinched wires,
contact with sharp edges or contact with hot exhaust
manifolds or pipes.
Basic Knowledge of Tools Required
NOTE: Lack of basic knowledge of this powertrain when
performing diagnostic procedures could result in an
incorrect diagnosis or damage to powertrain
components. Do not attempt to diagnose a powertrain
problem without this basic knowledge.
A basic understanding of hand tools is necessary to effec-
tively use this section of the Service Manual.
Serial Data Communications
Class II Serial Data Communications
This vehicle utilizes the “Class II” communication system.
Each bit of information can have one of two lengths: long
or short. This allows vehicle wiring to be reduced by
transmitting and receiving multiple signals over a single
wire. The messages carried on Class II data streams are
also prioritized. If two messages attempt to establish
communications on the data line at the same time, only
the message with higher priority will continue. The device
with the lower priority message must wait. The most
significant result of this regulation is that it provides Tech 2
manufacturers with the capability to access data from any
make or model vehicle that is sold.

6E–39 ENGINE DRIVEABILITY AND EMISSIONS
The data displayed on the other Tech 2 will appear the
same, with some exceptions. Some Tech 2s will only be
able to display certain vehicle parameters as values that
are a coded representation of the true or actual value. For
more information on this system of coding, refer to
Decimal/Binary/Hexadecimal Conversions. On this
vehicle Tech 2 displays the actual values for vehicle
parameters. It will not be necessary to perform any
conversions from coded values to actual values.
On-Board Diagnostic (OBD)
On-Board Diagnostic Tests
A diagnostic test is a series of steps, the result of which is
a pass or fail reported to the diagnostic executive. When
a diagnostic test reports a pass result, the diagnostic
executive records the following data:
The diagnostic test has been completed since the last
ignition cycle.
The diagnostic test has passed during the current
ignition cycle.
The fault identified by the diagnostic test is not
currently active.
W h e n a d i a g n o s t i c t e s t r e p o r t s a fail result, the diagnostic
executive records the following data:
The diagnostic test has been completed since the last
ignition cycle.
The fault identified by the diagnostic test is currently
active.
The fault has been active during this ignition cycle.
The operating conditions at the time of the failure.
Remember, a fuel trim DTC may be triggered by a list of
vehicle faults. Make use of all information available (other
DTCs stored, rich or lean condition, etc.) when
diagnosing a fuel trim fault.
Comprehensive Component Monitor
Diagnostic Operation
Input Components:
Input components are monitored for circuit continuity and
out-of-range values. This includes rationality checking.
Rationality checking refers to indicating a fault when the
signal from a sensor does not seem reasonable, i.e.
Throttle Position (TP) sensor that indicates high throttle
position at low engine loads or MAP voltage. Input
components may include, but are not limited to the
following sensors:
Vehicle Speed Sensor (VSS)
Crankshaft Position (CKP) sensor
Knock Sensor (KS)
Throttle Position (TP) sensor
Engine Coolant Temperature (ECT) sensor
Camshaft Position (CMP) sensor
Manifold Absolute Pressure (MAP) sensor
Mass Air Flow (MAF) sensorIn addition to the circuit continuity and rationality check,
the ECT sensor is monitored for its ability to achieve a
steady state temperature to enable closed loop fuel
control.
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 circuits:
Idle Air Control (IAC) Motor
Electronic Transmission controls
A/C relays
Cooling fan relay
VSS output
MIL control
Cruise control inhibit
Refer to PCM 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. For example, the EGR diagnostic active test will
force the EGR valve open during closed throttle decel
and/or force the EGR valve closed during a steady state.
Either action should result in a change in manifold
pressure.
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.

6E–40
ENGINE DRIVEABILITY AND EMISSIONS
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:
Oxygen sensors
Oxygen sensor heaters
EGR
Catalyst monitoring
Enable Criteria
The term “enable criteria” is engineering language for the
conditions necessary for a given diagnostic test to run.
Each diagnostic has a specific list of conditions which
must be met before the diagnostic will run. “Enable
criteria” is another way of saying “conditions required”.
The enable criteria for each diagnostic is listed on the first
page of the DTC description under the heading
“Conditions for Setting the DTC”. Enable criteria varies
with each diagnostic, and typically includes, but is not
limited to the following items:
engine speed
vehicle speed
ECT
MAF/MAP
barometric pressure
IAT
TP
fuel trim
TCC enabled
A/C on
Tr i p
Technically, a trip is a key on-run-key off cycle in which all
the enable criteria for a given diagnostic are met, allowing
the diagnostic to run. Unfortunately, this concept is not
quite that simple. A trip is official when all the enable
criteria for a given diagnostic are met. But because the
enable criteria vary from one diagnostic to another, the
definition of trip varies as well. Some diagnostic are run
when the vehicle is at operating temperature, some when
the vehicle first start up; some require that the vehicle be
cruising at a steady highway speed, some run only when
the vehicle is idle; some diagnostics function with the
TCC disables. Some run only immediately following a
cold engine start-up.
A trip then, is defined as a key on-run-key off cycle in
which the vehicle was operated in such a way as to satisfy
the enables criteria for a given diagnostic, and this
diagnostic will consider this cycle to be one trip. However,
another diagnostic with a different set of enable criteria
(which were not met) during this driving event, would not
consider it a trip. No trip will occur for that particular
diagnostic until the vehicle is driven in such a way as to
meet all the enable criteria.
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
following:
Commanding the MIL (“Check Engine” lamp) on and
off
DTC logging and clearing
Freeze Frame data for the first emission related DTC
recorded
Non-emission related Service Lamp (future)
Operating conditions Failure Records buffer, (the
number of records will vary)
Current status information on each diagnostic
The Diagnostic Executive records DTCs and turns on the
MIL when emission-related faults occur. It can also turn
off the MIL if the conditions cease which caused the DTC
to set.
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). However, OBD requires that the it illuminate under
a strict set of guide lines.
Basically, the MIL is turned on when the PCM detects a
DTC that will impact the vehicle emissions.
The MIL is under the control of the Diagnostic Executive.
The MIL will be turned on if an emissions-related
diagnostic test indicates a malfunction has occurred. It
will stay on until the system or component passes the
same test, for three consecutive trips, with no
emissionsrelated faults.
Extinguishing the MIL
When the MIL is on, the Diagnostic Executive will turn off
the MIL after
three consecutive trips that a “test passed”
has been reported for the diagnostic test that originally
caused the MIL to illuminate.
Although the MIL has been turned off, the DTC will remain
in the PCM memory (both Freeze Frame and Failure
Records) until
forty(40) warm-up cycles after no faults
have been completed.

6E–41 ENGINE DRIVEABILITY AND EMISSIONS
If the MIL was set by either a fuel trim or misfire-related
DTC, additional requirements must be met. In addition to
the requirements stated in the previous paragraph, these
requirements are as follows:
The diagnostic tests that are passed must occur with
375 RPM of the RPM data stored at the time the last
test failed.
Plus or minus ten (10) percent of the engine load that
was stored at the time the last failed.
Similar engine temperature conditions (warmed up or
warming up ) as those stored at the time the last test
failed.
Meeting these requirements ensures that the fault which
turned on the MIL has been corrected.
The MIL (“Check Engine” lamp) is on the instrument
panel and has the following function:
It informs the driver that a fault affects vehicle emission
levels has occurred and that the vehicle should be
taken for service as soon as possible.
As a bulb and system check, the MIL will come “ON”
with the key “ON” and the engine not running. When
the engine is started, the MIL will turn “OFF.”
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 ll) 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
Each DTC is directly related to a diagnostic test. The
Diagnostic Management System sets DTC based on the
failure of the tests during a trip or trips. Certain tests must
fail two (2) consecutive trips before the DTC is set. The
following are the four (4) types of DTCs and the
characteristics of those codes:
Ty p e A
Emissions related
Requests illumination of the MIL of the first trip with a
fail
Stores a History DTC on the first trip with a fail
Stores a Freeze Frame (if empty)
Stores a Fail Record
Updates the Fail Record each time the diagnostic
test fails
Ty p e B
Emissions related
“Armed” after one (1) trip with a fail
“Disarmed” after one (1) trip with a pass
Requests illumination of the MIL on the second
consecutive trip
with a fail
Stores a History DTC on the second consecutive trip
with a fail (The DTC will be armed after the first fail)
Stores a Freeze Frame on the second consecutive
trip with a fail (if empty)
Stores a Fail Record when the first test fails (not
dependent on
consecutive trip fails)
Updates the Fail Record each time the diagnostic
test fails
Type C (if the vehicle is so equipped)
Non-Emissions related
Requests illumination of the Service Lamp or the
service message on the Drive Information Center
(DIC) on the
first trip with a fail
Stores a History DTC on the first trip with a fail
Does not store a Freeze Frame
Stores Fail Record when test fails
Updates the Fail Record each time the diagnostic
test fails
Type D (Ty p e D non-emissions related are not utilized
on certain vehicle applications).
Non-Emissions related
Dose not request illumination of any lamp
Stores a History DTC on the first trip with a fail
Does not store a Freeze Frame
Stores Fail Record when test fails
Updates the Fail Record each time the diagnostic
test fails
IMPORTANT:Only four Fail Records can be stored.
Each Fail Record is for a different DTC. It is possible that
there will not be Fail Records for every DTC if multiple
DTCs are set.
Storing and Erasing Freeze Frame Data and Failure
Records
The data captured is called Freeze Frame data. The
Freeze Frame data is very similar to a single record of
operating conditions. Whenever the MIL is illuminated,
the corresponding record of operating conditions is
recorded to the Freeze Frame buffer.
Data from these faults take precedence over data
associated with any other fault. The Freeze Frame data
will not be erased unless the associated history DTC is
cleared.
Each time a diagnostic test reports a failure, the current
engine operating conditions are recorded in the
Failure
Records
buffer. A subsequent failure will update the
recorded operating conditions. The following operating
conditions for the diagnostic test which failed
typically
include the following parameters:
Air Fuel Ratio
Air Flow Rate
Fuel Trim
Engine Speed
Engine Load
Engine Coolant Temperature
Vehicle Speed
TP Angle
MAP/BARO
Injector Base Pulse Width
Loop Status

6E–42
ENGINE DRIVEABILITY AND EMISSIONS
Intermittent Malfunction Indicator Lamp
In the case of an “intermittent” fault, the MIL (“Check
Engine” lamp) may illuminate and then (after three trips)
go “OFF”. However, the corresponding diagnostic trouble
code will be stored in the memory. When unexpected
diagnostic trouble codes appear, check for an intermittent
malfunction.
A diagnostic trouble code may reset. Consult the
“Diagnostic Aids” associated with the diagnostic trouble
code. A physical inspection of the applicable sub-system
most often will resolve the problem.
Data Link Connector (DLC)
The provision for communication with the control module
is the Data Link Connector (DLC). The DLC is used to
connect to Tech 2. Some common uses of Tech 2 are
listed below:
Identifying stored Diagnostic Trouble Codes (DTCs).
Clearing DTCs.
Performing output control tests.
Reading serial data.
TS24064
Verifying Vehicle Repair
Verification of vehicle repair will be more comprehensive
for vehicles with OBD system diagnostic. Following a
repair, the technician should perform the following steps:
1. Review and record the Fail Records and/or Freeze
Frame data for the DTC which has been diagnosed
(Freeze Frame data will only be stored for an A or B
type diagnostic and only if the MIL has been
requested).
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the Fail
Records and/or Freeze Frame data.
4. Monitor the DTC status information for the specific
DTC which has been diagnosed until the diagnostic
test associated with that DTC runs.
Following these steps are very important in verifying
repairs on OBD systems. Failure to follow these steps
could result in unnecessary repairs.
Reading Diagnostic Trouble Codes Using
A Tech 2
The procedure for reading diagnostic trouble code(s) is to
used a diagnostic Tech 2. When reading DTC(s), follow
instructions supplied by Tech 2 manufacturer.
Clearing Diagnostic Trouble Codes
IMPORTANT:Do not clear DTCs unless directed to do
so by the service information provided for each diagnostic
procedure. When DTCs are cleared, the Freeze Frame
and Failure Record data which may help diagnose an
intermittent fault will also be erased from memory.
If the fault that caused the DTC to be stored into memory
has been corrected, the Diagnostic Executive will begin to
count the “warm-up” cycles with no further faults
detected, the DTC will automatically be cleared from the
PCM memory.
To clear Diagnostic Trouble Codes (DTCs), use the
diagnostic Tech 2 “clear DTCs”. When clearing DTCs
follow instructions supplied by the tool manufacturer.
When Tech 2 is not available, DTCs can also be cleared
by disconnecting
one of the following sources for at least
thirty (30) seconds.
NOTE: To prevent system damage, the ignition key must
be “OFF” when disconnecting or reconnecting battery
power.
The power source to the control module. Examples:
fuse, pigtail at battery PCM connectors etc.
The negative battery cable. (Disconnecting the
negative battery cable will result in the loss of other
on-board memory data, such as preset radio tuning).

6E–43 ENGINE DRIVEABILITY AND EMISSIONS
Te c h 2
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2 Tech
2 user guide.
901RW180
Legend
(1) PCMCIA Card
(2) RS 232 Loop Back Connector(3) SAE 16/19 Adaptor
(4) DLC Cable
(5) Tech–2
Tech 2 Features
1. Tech 2 is 12 volt system. Do not apply 24 volt.
2. After connect and/or install Tech 2 body, Vehicle
Communications Interface (VCI) module, PCMCIA
card and DLC connector, connect them to the vehicle
DLC.
3. After power off to the Tech 2, remove and reinstall the
PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes
which is 10 times greater than the memory of the Tech
1 Mass Storage Cartridge.5. The Tech 2 has the capability of two snapshots.
6. The PCMCIA card is sensitive to magnetism and
static electricity, so care should be taken in the
handling of the card.
7. The Tech 2 can plot a graph when replaying a
snapshot.
8. Always return to the Main Menu to press EXIT key
several times before shutting down.
9. To clear Diagnostic Trouble Codes (DTCs), open
Application Menu and press “F1: Clear DTC Info”.