Back OPEL FRONTERA 1998 Workshop Manual

6E–172
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1657 (Flash DTC 76)
ECM Main Relay Circuit Open/Short
060RW135
Circuit Description
The ECM main relay circuit receives current through ECM
50A fuse from the battery, current flowing in the order of
the ECM main relay and ECM.
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 P1657 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.

6E–174
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1589 (Flash DTC 47)
Transmission SW Circuit Open/Short
060RW131
Circuit Description
The trans mission SW circuit receives current through
ELEC IG 10A fuse from the battery, current flowing in the
order of the trans mission SW and ECM.
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 P1589 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
throttle position display on the Tech 2 while moving
connectors and wiring harnesses related to the TP
sensor. A change in the display will indicate the
location of the fault.
If DTC P1589 cannot be duplicated, the information
included in the Failure Records data can be useful in
determining vehicle mileage since the DTC was last set.
DTC P1589 – Transmission Circuit Open/Short
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
2Check the Fuse 10A for a open circuit and replace the
Fuse if necessary.
Did the Fuse require replacement?
—Verify repairGo to Step 3

6E–176
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Symptom Diagnosis
Preliminary Checks
Before using this section, perform the “On–Board
Diagnostic (OBD) System Check” and verify all of the
following items:
The powertrain control module (ECM) and
malfunction indicator lamp (MIL) (CHECK ENGINE
lamp) are operating correctly.
There are no DTC(s) stored.
Tech–2 data is within normal operating range. Refer
to
Typical Scan Data Values.
Verify the customer complaint and locate the correct
symptom in the table of contents. Perform the
procedure included in the symptom chart.
Visual/Physical Check
Several of the symptom procedures call for a careful
visual/physical check. This can lead to correcting a
problem without further checks and can save valuable
time.
This check should include the following items:
ECM grounds for cleanliness, tightness and proper
location.
Vacuum hoses for splits, kinks, and proper
connections, as shown on the “Vehicle Emission
Control Information” label. Check thoroughly for any
type of leak or restriction.
Air intake ducts for collapsed or damaged areas.
Injector wires for cracking, hardness, and carbon
tracking.
Wiring for proper connections, pinches and cuts.
Intermittents
IMPORTANT:An intermittent problem may or may not
turn on the malfunction indicator lamp (MIL) or store a
DTC. DO NOT use the Diagnostic Trouble Code (DTC)
charts for intermittent problems. The fault must be
present to locate the problem.
Most intermittent problems are caused by faulty electrical
connections or wiring. Perform a careful visual/physical
check for the following conditions:
Poor mating of the connector halves or a terminal not
fully seated in the connector (backed out).
Improperly formed or damaged terminal.
All connector terminals in the problem circuit should
be carefully checked for proper contact tension.
Poor terminal–to–wire connection. This requires
removing the terminal from the connector body to
check.
Road test the vehicle with a Digital Multimeter
(5-8840-0285-0) connected to a suspected circuit. An
abnormal voltage when the malfunction occurs is a good
indication that there is a fault in the circuit being
monitored.
Use a scan tool to help detect intermittent conditions. The
scan tools have several features that can be used to
locate an intermittent condition. Use the following feature
to find intermittent faults:
Using a Tech–2 “Freeze Frame” buffer or “Failure
Records” buffer can aid in locating an intermittent
condition. Review and record the information in the
freeze frame or failure record associated with the
intermittent DTC being diagnosed. The vehicle can
be driven within the conditions that were present
when the DTC originally set.
To check for loss of diagnostic code memory, disconnect
the MAP sensor and idle the engine until the MIL (CHECK
ENGINE lamp) comes on. DTC P0107 should be stored
and kept in memory when the ignition is turned “OFF.” If
not, the ECM is faulty. When this test is completed, make
sure that you clear the DTC P0107 from memory.
An intermittent MIL (CHECK ENGINE lamp) with no
stored DTC may be caused by the following:
MIL (CHECK ENGINE lamp) wire to ECM shorted to
ground.
Poor ECM grounds. Refer to the ECM wiring
diagrams.
Check for improper installation of electrical options such
as lights, cellular phones, etc.
Check for an open diode across the A/C compressor
clutch and check for other open diodes (refer to wiring
diagrams in
Electrical Diagnosis).
If problem has not been found, refer to
ECM Connector
Symptom
tables.

6E–180
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Surges and/or Chuggles Symptom
StepNo Ye s Va l u e ( s ) Action
101. Check the exhaust system for possible restriction:
Inspect the exhaust system for damaged or
collapsed pipes.
Inspect the muffler for heat distress or possible
internal failure.
Check for a possible plugged catalytic
converter by checking the exhaust system
back pressure. Refer to
Restricted Exhaust
System Check
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 11
111. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Te c h 2 d a t a
Freeze Frame data/Failure Records buffer
All electrical connections within a suspected
circuit and/or system.
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repair
Contact
Te c h n i c a l
Assistance

6E–181 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Lack of Power, Sluggish or Spongy Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Engine delivers less than expected power. Little or no
increase in speed when accelerator pedal is pushed
down part-way.
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?
—Verify repairGo to Step 3
3Was a visual/physical check performed?
—Go to Step 4
Go to Visual/
Physical
Check
41. Remove and check the air filter element for dirt or
restrictions. Refer to
Air Intake System in
On-Vehicle Service.
2. Replace the air filter element if necessary.
Was a repair required?
—Verify repairGo to Step 5
51. Check AP sensor system. Refer to AP sensor
diagnostic
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 6
61. Check for water-or alcohol-contaminated fuel.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
71. Using a Tech 2, Injector test.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 8
81. Check the ECM grounds for the cleanliness,
tightness and proper locations. 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 9
91. Check the exhaust system for possible restriction:
Inspect the exhaust system for damaged or
collapsed pipes.
Inspect the muffler for heat distress or possible
internal failure.
Check for a possible plugged catalytic
converter by checking the exhaust system
back pressure. Refer to
Restricted Exhaust
System Check
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 10
101. Check the torque converter clutch (TCC) for proper
operation. Refer to
Transmission Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 11

6E–223 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Weather-Pack Connector
To o l s R e q u i r e d
5-8840-0388-0 Weather-Pack II Terminal Remover
Removal Procedure
A Weather-Pack connector can be identified by a rubber
seal at the rear of the connector. This engine room
connector protects against moisture and dirt, which could
from oxidation and deposits on the terminals. This
protection is important, because of the low voltage and
the low amperage found in the electronic systems.
1. Open the secondary lock hinge on the connector.
070
2. Use tool 5-8840-0388-0 or the equivalent to remove
the pin and the sleeve terminals. Push on
5-8840-0388-0 to release.
NOTE: Do the use an ordinary pick or the terminal may
be bent or deformed. Unlike standard blade terminals,
these terminals cannot be straightened after they have
been improperly bent.
071
3. Cut the wire immediately behind the cable seal.
072
Installation Procedure
Make certain the connectors are properly seated and all
of the sealing rings are in place when you reconnect the
leads. The secondary lock hinge provides a backup
locking feature for the connector. The secondary lock
hinge is used for added reliability. This flap should retain
the terminals even if the small terminal lock tangs are not
positioned properly.
Do not replace the Weather-Pack connections with
standard connections. Read the instructions provided
with the Weather-Pack connector and terminal packages.
1. Replace the terminal.
2. Slip the new seal onto the wire.
3. Strip 5 mm (0.2”) of insulation from the wire.
4. Crimp the terminal over the wire and the seal.
073

6E–224
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
5. Push the terminal and the connector to engage the
locking tangs.
070
6. Close the secondary locking hinge.
Com-Pack III
General Information
The Com-Pack III terminal looks similar to some
Weather-Pack terminals. This terminal is not sealed and
is used where resistance to the environment is not
required. Use the standard method when repairing a
terminal. Do not use the Weather-Pack terminal tool
5-8840-0388-0 or equivalent. These will damage the
terminals.
Metri-Pack
To o l s R e q u i r e d
5-8840-0632-0 Terminal Remover
Removal Procedure
S o m e c o n n e c t o r s u s e t e r m i n a l s c a l l e d M e t r i - P a c k S e r i e s
150. These may be used at the engine coolant
temperature (ECT) sensor.
1. Slide the seal (1) back on the wire.2. Insert the 5-8840-0632-0 tool or equivalent (3) in
order to release the terminal locking tang (2).
060
3. Push the wire and the terminal out through the
connector. If you reuse the terminal, reshape the
locking tang.
Installation Procedure
Metri-Pack terminals are also referred to as “pull-to-seat”
terminals.
1. In order to install a terminal on a wire, the wire must be
inserted through the seal (2) and through the
connector (3).
2. The terminal (1) is then crimped onto the wire.
061
3. Then the terminal is pulled back into the connector to
seat it in place.

7A–12
AUTOMATIC TRANSMISSION (4L30–E)
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart
Perform Preliminary Inspection First!
When the “CHECK TRANS” indicator is flashing, it
indicates that a problem related to the transmission, the
Powertrain Control Module (PCM), or the vehicle harness
has occurred.The system is now operating in a “BACKUP MODE”
where the risk of further damaging the transmission has
been reduced. The vehicle may be shifted manually.
If the initial problem is intermittent or seldom, switching
the engine OFF/ON might allow normal operation again
until the problem reoccurs.
F07RT013

7A–21 AUTOMATIC TRANSMISSION (4L30–E)
Chart 15b: Possible Causes Of High Line Pressure
NOTE: If transmission is operating in backup mode, high
line pressure will be present.
Step
ActionYe sNo
1Check for defective throttle position sensor.
Was the problem found?Replace throttle
position sensor.
Go to Step 2.
2Check for a stuck force motor plunger (404). (Open
circuit/intermittent) (Adapter case valve body)
Was the problem found?Replace force
motor plunger
(404)
Go to Step 3
3Check for a stuck feed limit valve (412). (Adapter case valve body)
Was the problem found?Replace force
motor plunger
(412)
Go to Step 4
4Check converter bolts (4 & 5).
Was the problem found?Tighten converter
bolts (4 & 5)
Go to Step 5
5Check for a stuck pressure regulator valve (208). (Oil pump)
Was the problem found?Replace pressure
regulator valve
(208)
Go to Step 6
6Check for a stuck boost valve (205). (Oil pump)
Was the problem found?Replace boost
valve (205)
Go to Step 7
7Check for internal leaks.
– Check balls missing or out of location in valve bodies
– Seals cut or missing
– Gaskets defective, etc.
Was the problem found?Install balls, or
correct ball
location
Replace seals
Replace gaskets
—

7A–22
AUTOMATIC TRANSMISSION (4L30–E)
Chart 16: Possible Causes Of
Transmission Fluid Leaks
Before attempting to correct an oil leak, the actual source
of the leak must be determined. In many cases, the
source of the leak may be difficult to determine due to
“wind flow” around the engine and transmission.
The suspected area should be wiped clean before in-
specting for the source of the leak.Oil leaks around the engine and transmission are gener-
ally carried toward the rear of the vehicle by the air
stream. In determining the source of an leak, the following
two checks should be made:
1. With the engine running, check for external line
pressure leaks.
2. With the engine off, check for oil leaks due to the
raised oil level caused by drainback of converter oil
into the transmission.
Possible Causes Of Fluid Leaks Due To Sealing Malfunction
240RX008
Legend
(1) Electrical Connector (Main Case) Seal
(2) Transmission Vent (Breather)
(3) Speed Sensor O–Ring
(4) Extension (Adapter) Lip Seal
(5) Extension (Adapter) to Main Case Gasket
(6) Overfill and Oil Drain Screws Gasket
(7) Oil Pan Gasket (Main Case)
(8) Selector Shaft Seal(9) Oil Cooler Connectors (2)
(10) Oil Pan Gasket (Adapter Case)
(11) Converter housing attaching bolts not correctly
torqued
(12) Converter Housing Lip Seal
(13) Line Pressure Tap Plug
(14) Electrical Connector (Adapter Case) Seal
(15) Adapter Case Seal Rings (2)