charging OPEL FRONTERA 1998 Service Manual

ENGINE ELECTRICAL 6D – 3
ON-VEHICLE SERVICE
BATTERY CHARGING
Observe the following safety precautions when
charging the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during the
charging procedure.
Battery charging should be discontinued or the rate
of charge reduced if the battery feels hot to the
touch.
Battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas or
spew electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue
dot or ring, it may be necessary to jiggle or tilt the
battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be
either quick-charged or slow-charged in the same
manner as other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
JUMP STARTING
JUMP STARTING WITH AN AUXILIARY
(BOOSTER) BATTERY
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: Failure to carefully follow the jump
starting procedure could result in the following:
1. Serious personal injury, particularly to your
eyes.
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one or
both vehicles.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode. Remove any rings, watches, or other jewelry
before working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with your
eyes or skin.
Never allow battery fluid to come in contact with fabrics
or painted surfaces.
Battery fluid is a highly corrosive acid.Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface, immediately and
thoroughly rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of the reach of young
children.
JUMP STARTING PROCEDURE
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector lever in the “PARK”
position.
If the vehicle is equipped with a manual
transmission place the shift lever in the “NEUTRAL”
position.
Turn “OFF” the ignition.
Turn “OFF” all lights and any other accessory
requiring electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the
positive terminal of the discharged battery.
Do not allow the vehicles to touch each other.
This will cause a ground connection, effectively
neutralizing the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the
negative terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the A/C compressor
bracket or the generator mounting bracket) of the
vehicle with the discharged battery.
This ground connection must be at least 450 mm
(18 in) from the battery of the vehicle whose battery
is being charged.
WARNING: Never attach the end of the jumper
cable directly to the negative terminal of the dead
battery.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical
accessories have been turned “OFF”.
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above
directions in the reverse order.
Be sure to first disconnect the negative cable from
the vehicle with the discharged battery.

ENGINE ELECTRICAL 6D – 15
CHARGING SYSTEM
GENERAL DESCRIPTION
GENERATOR
CHARGING CIRCUIT
The charging system is the IC integral regulator
charging system and its main components are
connected as shown in Figure.
The regulator is a solid state type and it is mounted
along with the brush holder assembly inside the
generator installed on the rear end cover.The generator does not require particular maintenance
such as voltage adjustment. The rectifier connected to
the stator coil has nine diodes to transform A.C. voltage
into D.C. voltage. This D.C. voltage is connected to the
output terminal of generator.
A06RW001
Condenser
GeneratorStator Coil
IC RegulatorStarter
SW
Rotor Coil
Battery
P F
EBS LRelay B
S
L
QOS
065R200028

6D – 16 ENGINE ELECTRICAL
DIAGNOSIS
GENERAL ON-VEHICLE INSPECTION
The operating condition of the charging system is
indicated by the charge warning lamp. The warning
lamp comes on when the starter swtich is turned to
“ON” position. The charging system operates normallyif the lamp goes off when the engine starts. If the
warning lamp shows abnormality or if undercharged or
overcharged battery condition is suspected, perform
diagnosis by checking the charging system as follows:
Condenser
GeneratorStator Coil
IC RegulatorStarter
SW
Rotor Coil
Battery
P F
EBS LRelay B
S
L
QOS
065R200028
1. Check visually the belt and wiring connector.
2. With the engine in stop status, turn the starter
switch to “ON” position and observe the warning
lamp.
1) If lamp does not come on:
Disconnect wiring connector from generator,
and ground terminal “L” on connector side.
2) If lamp comes on:
Repair or replace the generator.

ENGINE ELECTRICAL 6D – 21
Rectifier Assembly
1. Measure the resistance between each diode
terminal and aluminum diode fin in forward and
reverse directions with the connection of the tester
leads switched. The diodes are normal if resistance
is nearly zero ohms in one direction and is infinitely
high in the other direction.
2. If a diode has no resistance or equal resistance in
both directions, it is defective and should be
replaced together with the holder.
IC Regulator Assembly
Connect a variable resistor, two 12V batteries, a fixed
resistor, and a voltmeter to the IC regulator as shown in
illustration.
a. Measuring equipment specifications
1. Fixed resistor (R1) : 10 Ohms / 3W
2. Variable resistor (Rv) : 0 – 300 Ohms / 12W
3. Batteries (BAT1, BAT2) : 12V (2 Batteries)
4. DC voltmeter : 0 – 50V / 0.5 steps (4 Check points)
b. Measuring procedure
1. Measure the voltage “V1” across the first battery
(BAT1). If the reading is between 10 and 13 volts,
the battery is normal.
2. Measure the voltage “V3” across both the batteries
(BAT1, BAT2). If the reading is between 20 and 26
bolts, the batteries are normal.
3. Gradually increase the resistance of the variable
resistor from zero. Measure the voltage “V2” (the
voltage across the F and E terminals).
Check to see that the voltage across “V1” changes
at this time. If there is no change, the voltage
regulator is faulty and must be replaced.
4. Measure the voltage at “V4” (the voltage across the
variable resistor center tap and terminal E with the
variable resistor resistance held constant). The
measure voltage should be within the specified
(14.4 ± 0.3 volts) limits. If it is not, the regulator
must be replaced.
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
NOTE:
1) Never make battery connections with polarities
reversed, or battery will be shorted via the diodes.
This will cause damage to the diodes.
2) Do not connect generator B terminal to ground; it is
connected directly to the battery.
This cable will burn if it is connected to ground.
3) Make sure to disconnect the positive (+) terminal of
the battery when quick-charging battery.
Diodes may be damaged due to abnormal pulse
voltage generated by the quick charger.
4) When reassembling the front section to rear
section, insert a stiff wire into hole in the rear face
of the rear cover from the outboard side to support
the brush in raised position, then insert the front
section to which rotor is assembled.
5) Reassemble parts carefully to be sure they fit into
their original position, paying attention to the
insulated portions.
6) Wipe insulating tubes, washers and plates clean
and install them in position carefully to avoid getting
oil or grease on them.
066RS036
R
EBS
R1RV
BAT2 BAT1
V2V3
V4V1＋
−
＋
−
066RW029

6E–159 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0562 (Flash DTC 35)
System Voltage Too Low
Circuit Description
The engine control module (ECM) monitors the system
voltage on the ignition feed terminals to the ECM. A
system voltage DTC will set whenever the voltage is
above a calibrated value.
Action Taken When the DTC Sets
The ECM will not illuminate the malfunction indicator
lamp (MIL).
The ECM will store as Failure Records only conditions
which were present when the DTC was set. This
information will not be stored as Freeze Frame data.
Conditions for Clearing the MIL/DTC
DTC P0563 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the ECM battery
feed.
Diagnostic Aids
If the DTC sets when an accessory is operated, check for
a poor connection or defective accessory.
DTC P0562 – System Voltage Too Low
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
2Using a DVM, measure the battery voltage at the
battery.
Is the battery voltage greater than the specified value?
11.5 VGo to Step 3
Charge
battery, then
go to
Step 3
31. Install a Tech 2.
2. Select “Ignition Volts” on the Tech 2.
3. Start the engine and raise the engine speed to the
specified value.
4. Load the electrical system by turning on the
headlights, high blower, etc.
Is the ignition voltage approximately equal to the
specified value?
2000 RPM
12.8-14.1 V
Go to Step 4
Go to
Starting/
Charging
41. Ignition “OFF.”
2. Disconnect the ECM connector at the ECM.
3. Using a DVM, measure the battery voltage at the
ECM connector.
Is it approximately equal to battery voltage?
—
Check for
excessive
current draw
with ignition
“OFF,” engine
“OFF.”
Go to Step 5
51. Check for faulty connections at the ECM harness
terminals.
2. Repair as necessary.
Was a repair necessary?
—Verify repairGo to Step 6
6Check for an open battery feed circuit to the ECM.
Is the action complete?
—Verify repairGo to Step 7
7Replace the ECM (Refer to the Data Programming in
Case of ECM change).
Is the action complete?
—Verify repair—

6E–206
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
3. Disconnect the electrical connector from the OT
sensor.
4. Remove the OT sensor.
035RW061
Installation Procedure
1. Install the OT sensor.
035RW061
2. Connect the OT sensor electrical connector.
3. Install the battery.
035RW095
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–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.

TRANSMISSION CONTROL SYSTEM (4L30–E)7A1–21
NOTE: To use the DTC again to identify a problem, you
will need to reproduce the fault or the problem. This may
require a new test drive or just turning the ignition on (this
depends on the nature of the fault).
1. IF you have a Tech2:
1. Connect the Tech2 if it is still not connected
GOTHROUGH Tech2 OBD II CONNECTION.
2. Push “F4” and answer “Yes” to the question “Do
you really want to clear the codes?”
a. When a malfunction remains as it is the Tech2
displays “4L30E CODES NOT CLEARED”. This
means that the problem is still there or that the
recovery was not done. Please GOTO DTC
CHECK.
b. When a malfunction has been repaired and the
recovery is done. The Tech2 displays “4L30E
CODES CLEARED”.
2. IF you have no Tech2:
To clear the DTC, remove Fuse “Stop, A/T CONT”
(C–14, 15A) for at least 10 seconds.
DTC Check
1. Diagnostic Trouble Codes (DTC) have been identified
by Tech2.
2. You have written the list of the DTCs. The order of the
malfunctions has no meanings for this PCM. Usually
only one or two malfunctions should be set for a given
problem.
3. Check directly the DTCs you identified. The DTCs are
sorted by number. Refer to Diagnostic Trouble Code
(DTC) Identification in this section.
PCM Precaution
The PCM can be damaged by:
1. Electrostatic discharge
2. The short circuit of some terminals to voltage or to
ground.
Electrostatic Discharge Damage Description:
1. Electronic components used to control systems are
often designed to carry very low voltage, and are very
susceptible to damage caused by electrostatic
discharge. It is possible for less than 100 volts of
static electricity to 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.2. 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 car
seat, in which a charge of as much as 25,000 volts
can build up. Charging by induction occurs when a
person with well insulated shoes stands near a highly
charged object and momentarily touches ground.
Charges for the same polarity are drained off, leaving
the person highly charged with the opposite polarity.
Static charges of either type can cause damage,
therefore, it is important to use care when handling
and testing electronic components.
NOTICE: To prevent possible electrostatic
discharge damage:
1. Do not touch the PCM connector pins or soldered
components on the PCM circuit board.
2. Be sure to follow the guidelines listed below if
servicing any of these electronic components:
3. Do not open the replacement part package until it is
time to install the part.
4. Avoid touching electrical terminals of the part.
5. Before removing the part from its package, ground
the package to a known good ground on the vehicle.
6. Always touch a known good ground before handling
the part. This step should be repeated before
installing the part if the part has been handled while
sliding across the seat, while sitting down from a
standing position or while walking some distance.
Information On PCM
1. The Powertrain Control Module (PCM) is located in
the center console and is the control center of the
electronic transmission control system.
2. The PCM must be maintained at a temperature below
185
F (85C) at all times. This is most essential if the
vehicle is put through a paint baking process. The
PCM will become inoperative if its temperature
exceeds 85
C (185F). Therefore, it is
recommended that the PCM be removed or that
temporary insulation be placed around the PCM
during the time the vehicle is in a paint oven or other
high temperature process.
3. The PCM is designed to process the various inputs
and then respond by sending the appropriate
electrical signals to control transmission upshift,
downshift, shift feel and torque converter clutch
engagement.
4. The PCM constantly interprets information from the
various sensors, and controls the systems that affect
transmission and vehicle performance. By analyzing
operational problems, the PCM is able to perform a
diagnostic function by displaying DTC(s) and aid the
technician in making repairs.
Intermittent Conditions
If the Tech2 displays a diagnostic trouble code as
intermittent, or if after a test drive a DTC does not
reappear though the detection conditions for this DTC are
present, the problem is most likely a faulty electrical

TRANSMISSION CONTROL SYSTEM (4L30–E)7A1–27
DTC P0560 System Voltage Malfunction
D07RW030
Circuit Description
Circuit WHT is the battery voltage feed for the PCM.
Circuit RED/BLU is the ignition voltage feed for the PCM.
This DTC detects a low voltage or a high voltage. This is a
type “C” DTC.
Conditions For Clearing The DTC
System Voltage Low:
Engine speed is greater than 1,000 rpm.
System voltage is less than 10 volts at a maximum
transmission temperature of 150
C (302F).
System voltage is less than 7.3 volts at a minimum
transmission temperature of –40
C (–40F).
All conditions met for 4 seconds.
System Voltage High:
System voltage is greater than 16 volts for 2 seconds.
Action Taken When The DTC Sets
Fixed to 4th gear.
Maximum line pressure.
Inhibit TCC engagement.
The PCM will illuminate the CHECK TRANS Lamp.
Conditions For Clearing The DTC
The DTC can be cleared from the PCM history by
using a scan tool.
The PCM will turn off the CHECK TRANS Lamp after
three consecutive ignition cycles without a failure
reported.
The DTC will be cleared from history when the vehicle
has achieved 40 warmup cycles without a failure
reported.
The PCM will cancel the DTC default actions when
the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.
Diagnostic Aids
Charging the battery with a battery charger and jump
starting an engine may set DTC(s). If DTC(s) set
when an accessory is operated, check for faulty
connections or excessive current draw.
Check for faulty connections at the starter solenoid or
fusible link.
Check for loose/damaged terminals at generator.
Check belt wear/tension.
Test Description
The numbers below refer to the step numbers on the
diagnostic chart.
4. This test checks charging system voltage.
5. This test checks battery voltage input at the PCM.
7. This test checks ignition voltage input at the PCM.

7A1–28
TRANSMISSION CONTROL SYSTEM (4L30–E)
DTC P0560 System Voltage Malfunction
StepActionYe sNo
11. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”. Note: If any other DTCs
are present, refer to their applicable diagnostic charts before
continuing.
4. Using the J–39200 DVOM, measure the battery voltage
across the battery terminals. Record the measurement for
future reference.
Is the voltage higher than 10.5 volts?
Go to Step 2
Go to Engine
Electrical in
Engine section
2Start the engine and warm to normal operating temperature.
Is the generator/check engine light “on”?Go to Starting
and Charging
System in Engine
section
Go to Step 3
31. Increase the engine speed to 1,000–1,500 rpm.
2. Observe scan tool system voltage.
Is the system voltage within 13–15 volts.
Go to Step 4
Go to Starting
and Charging
System in Engine
section
41. Turn the ignition switch “off”.
2. Disconnect the J1(RED) and J3 (BLUE) PCM connector
(additional DTCs will set).
3. With the engine “off”, turn the ignition switch “on”.
4. Using the J39200 DVOM, measure the battery voltage input at
PCM connector terminals J1–A4 and J3–E16.
Is there a voltage variance between the voltage measured at the
battery (taken in Step 1) and at terminals J1–A4 and J3–E16 that
is greater than 0.5 volts?
Go to Step 5Go to Step 6
5Repair the high resistance condition in circuit WHT.
Was the circuit repaired?
Go to Step 10—
61. Disconnect the J3 (BLUE) PCM connector.
2. Measure the ignition voltage input at PCM connector terminals
J3–E16 and J3–F16.
Is there a voltage variance between the voltage measured at the
battery (taken in Step 1) and at terminals J3–E16 and J3–F16 that
is greater than 0.5 volts?
Go to Step 7Go to Step 8
7Repair the high resistance condition is circuit RED/BLU.
Was the circuit repaired?
Go to Step 10—
8Check PCM connector terminals J1–A4, J3–E16 and J3–F16 for
bent, damaged, or backed out connector pins. Also check for
weak terminal tension.
Was a problem found?
Go to Step 10Go to Step 9