fuel pump OPEL FRONTERA 1998 Service Manual

6E–319 ENGINE DRIVEABILITY AND EMISSIONS
Fuel Pump Relay
Removal Procedure
1. Remove the fuse and relay box cover from under the
hood.
2. Consult the diagram on the cover to determine which
is the correct relay.
3. Insert a small screwdriver into the catch slot on the
forward side of the fuel pump relay.
The screwdriver blade will release the catch inside.
T321092
4. Pull the relay straight up and out of the fuse and relay
box.
TS23976R
Installation Procedure
1. Insert the relay into the correct place in the fuse and
relay box with the catch slot facing forward.
2. Press down until the catch engages.
An audible “click” will be heard.
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3. Install the fuse and relay box cover.
Fuel Rail Assembly
Removal Procedure
NOTE:
Do not attempt to remove the fuel inlet fitting on the
fuel rail. It is staked in place. Removing the fuel inlet
fitting will result in damage to the fuel rail or the
internal O-ring seal.
Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminals and the injector spray tips.
Fittings should be capped and holes plugged during
servicing to prevent dirt and other contaminants from
entering open lines and passages.

6E–321 ENGINE DRIVEABILITY AND EMISSIONS
4. Connect the vacuum hose on Canister VSV and
positive crankcase ventilation hose.
5. Connect the connectors to manifold absolute
pressure sensor, solenoid valve, electric vacuum
sensing valve.
6. Connect the accelerator pedal cable to throttle body
and cable bracket.
7. Install the engine cover.
8. Connect the negative battery cable.
9. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel rail and in the injectors.
Fuel Tank
Removal Procedure
1. Disconnect the negative battery cable.
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank into an approved
container.
4. Install and tighten the drain plug.
Tighten
Tighten the drain plug to 20 Nꞏm (14 lb ft.).
5. Disconnect the fuel filler hose at the fuel tank.
6. Disconnect the air breather hose at the fuel tank.
TS23796
7. Remove the undercover retaining bolts.
8. Remove the undercover.
TS23797
9. Disconnect the wiring connector to the fuel pump.
10. Disconnect the wiring connector to the fuel gauge
unit.
11. Remove the fuel gauge unit connector from the
bracket.
12. Disconnect the EVAP vapor hose.
13. Disconnect the fuel supply hose.
14. Disconnect the fuel return hose.
Plug the hoses to prevent dust from entering the
hoses.
TS23769

6E–322
ENGINE DRIVEABILITY AND EMISSIONS
15. Remove the fuel tank retaining bolts on both sides.
16. Remove the fuel tank.
TS23770
Installation Procedure
1. Install the fuel tank.
Place the flanges on the left and right side of the
tank on the bracket.
2. Install the fuel tank retaining bolts.
Tighten
Tighten the fuel tank retaining bolts to 36 Nꞏm (27 lb
ft.).
TS23770
3. Connect the fuel return hose.
4. Connect the fuel supply hose.
5. Connect the EVAP vapor hose.
6. Connect the wiring connector for the fuel gauge unit.
7. Connect the fuel gauge wiring connector to the
bracket.
8. Connect the wiring connector for the fuel pump.
TS23769
9. Install the undercover.
10. Secure the undercover with the retaining bolts.
TS23797

6E–325 ENGINE DRIVEABILITY AND EMISSIONS
Spark Plug Gap Check
Check the gap of all spark plugs before installation.
Use a round wire feeler gauge to ensure an accurate
check.
Plugs installed with the wrong gap can cause poor
engine performance and excessive emissions.
Installation Procedure
NOTE: The plug must thread smoothly into the cylinder
head and be fully seated. Use a thread chaser if
necessary to clean the threads in the cylinder head.
Cross-threading or failure to fully seat the spark plug can
cause plug overheating, exhaust blow-by gas, or thread
damage. Do not overtighten the spark plugs. Over
tightening can cause aluminum threads to strip.
1. Install the spark plug in the engine. Use the
appropriate spark plug socket.
Tighten
Tighten the spark plug to 18 Nꞏm (13 lb ft.).
2. Install the ignition coil and spark plug boot over the
spark plug.
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3. Secure the ignition coil to the rocker cover with two
screws.
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4. Connect the electrical connector at the ignition coil.
5. Connect the negative battery cable.
Catalytic Converter
Removal and Installation Procedure
Refer to Engine Exhaust in Engine.
Air Conditioning Relay
Removal Procedure
1. Remove the fuse and relay box cover from under the
hood.
2. Consult the diagram on the cover to determine which
is the correct relay.
3. Insert a small screwdriver into the catch slot on the
forward side of the fuel pump relay.
The screwdriver blade will release the catch inside.
T321092

6E–328
ENGINE DRIVEABILITY AND EMISSIONS
3. Connect the vacuum hoses to the EVAP canister
purge solenoid.
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4. Connect the electrical connector to the EVAP canister
purge solenoid.
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Fuel Tank Vent Valve
Removal and Installation Procedure
Refer to Fuel Pump
Linear Exhaust Gas
Recirculation (EGR) Valve
Removal Procedure
1. Disconnect the negative battery cable.2. Disconnect the electrical connector at the EGR valve.
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3. Remove the bolt and the nut from the upper intake
manifold.
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4. Remove the EGR valve from the upper intake
manifold.
5. Remove the gasket from the upper intake manifold.
Installation Procedure
1. Install the gasket on the upper intake manifold.
2. Install the EGR valve on the upper intake manifold.
3. Secure the EGR valve and the gasket with the bolt
and the nut.

6E–339 ENGINE DRIVEABILITY AND EMISSIONS
0005
PCM Components
The PCM is designed to maintain exhaust emission levels
to government mandated standards while providing
excellent driveability and fuel efficiency. The PCM
monitors numerous engine and vehicle functions via
electronic sensors such as the throttle position (TP)
sensor, heated oxygen sensor (HO2S), and vehicle
speed sensor (VSS). The PCM also controls certain
engine operations through the following:
Fuel injector control
Ignition control module
Knock sensor
Automatic transmission shift functions
Cruise control
A/C clutch control
PCM Voltage Description
The PCM supplies a buffered voltage to various switches
and sensors. It can do this because resistance in the
PCM 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 (such as J 39200) to
assure accurate voltage readings.
The input/output devices in the PCM include
analog-to-digital converters, signal buffers, counters,
and special drivers. The PCM 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.
PCM Input/Outputs
Inputs – Operating Conditions Read
Air Conditioning “ON” or “OFF”
Engine Coolant Temperature
Crankshaft Position
Exhaust Oxygen Content
Electronic Ignition
Manifold Absolute Pressure
Battery Voltage
Throttle Position
Vehicle Speed
Fuel Pump Voltage
Power Steering Pressure
Intake Air Temperature
Mass Air Flow
Engine Knock
Camshaft Position
Outputs – Systems Controlled
Exhaust Gas Recirculation (EGR)
Ignition Control
Fuel Control
Idle Air Control
Electric Fuel Pump
Air Conditioning
Diagnostics
– Malfunction Indicator Lamp (Service Engine Soon
lamp)
– Data Link Connector (DLC)
– Data Output
Transmission Control Module
Alternator Gain Control
PCM Service Precautions
The PCM 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 PCM’s circuits unless
instructed to do so. These circuits should only be tested
Tech-2. The PCM should remain connected to the PCM
or to a recommended breakout box.
Reprogramming The PCM
The Trooper allow reprogramming of the PCM without
removing it from the vehicle . This provides a flexible and
cost-effective method of making changes in software
calibrations.
The service programming system (SPS) will not allow
incorrect software programming or incorrect calibration
changes.
Refer to the UBS 98model year Immobilizer Workshop
Manual.
Throttle Position (TP) Sensor
The throttle position (TP) sensor is a potentiometer
connected to the throttle shaft on the throttle body. The
PCM monitors the voltage on the signal line and
calculates throttle position. As the throttle valve angle is
changed (accelerator pedal moved), the TP sensor signal
also changes. At a closed throttle position, the output of

6E–342
ENGINE DRIVEABILITY AND EMISSIONS
PCM to calculate true sequential multiport fuel injection
(SFI). Loss of this signal will set a DTC P0341. If the CMP
signal is lost while the engine is running, the fuel injection
system will shift to a calculated sequential fuel injection
based on the last fuel injection pulse, and the engine will
continue to run. The engine can be restarted and will run
in the calculated sequential mode as long as the fault is
present, with a 1-in-6 chance of being correct.
Clear Flood Mode
Clear a flooded engine by pushing the accelerator pedal
down all the way. The PCM then de-energizes the fuel
injectors. The PCM holds the fuel injectors de-energized
as long as the throttle remains above 80% and the engine
speed is below 800 RPM. If the throttle position becomes
less than 80%, the PCM again begins to pulse the
injectors “ON” and “OFF,” allowing fuel into the cylinders.
Deceleration Mode
The PCM reduces the amount of fuel injected when it
detects a decrease in the throttle position and the air flow.
When deceleration is very fast, the PCM may cut off fuel
completely for short periods.
Engine Speed/Vehicle Speed/Fuel Disable
Mode
The PCM monitors engine speed. It turns off the fuel
injectors when the engine speed increase above 6400
RPM. The fuel injectors are turned back on when engine
speed decreases below 6150 RPM.
Fuel Cutoff Mode
No fuel is delivered by the fuel injectors when the ignition
is “OFF.” This prevents engine run-on. In addition, the
PCM suspends fuel delivery if no reference pulses are
detected (engine not running) to prevent engine flooding.
Fuel Injector
The sequential multiport fuel injection (SFI) fuel injector is
a solenoid-operated device controlled by the PCM. The
PCM energizes the solenoid, which opens a valve to allow
fuel delivery.
The fuel is injected under pressure in a conical spray
pattern at the opening of the intake valve. Excess fuel not
used by the injectors passes through the fuel pressure
regulator before being returned to the fuel tank.
A fuel injector which is stuck partly open will cause a loss
of fuel pressure after engine shut down, causing long
crank times.
0003
Fuel Metering System Components
The fuel metering system is made up of the following
parts:
The fuel injectors.
The throttle body.
The fuel rail.
The fuel pressure regulator.
The PCM.
The crankshaft position (CKP) sensor.
The camshaft position (CMP) sensor.
The idle air control (IAC) valve.
The fuel pump.
The fuel pump relay.
Basic System Operation
The fuel metering system starts with the fuel in the fuel
tank. An electric fuel pump, located in the fuel tank,
pumps fuel to the fuel rail through an in-line fuel filter. The
pump is designed to provide fuel at a pressure above the
pressure needed by the injectors. A fuel pressure
regulator in the fuel rail keeps fuel available to the fuel
injectors at a constant pressure. A return line delivers
unused fuel back to the fuel tank. Refer to
Section 6C f o r
further information on the fuel tank, line filter, and fuel
pipes.
Fuel Metering System Purpose
The basic function of the air/fuel metering system is to
control the air/fuel delivery to the engine. Fuel is delivered
to the engine by individual fuel injectors mounted in the
intake manifold near each intake valve.
The main control sensor is the heated oxygen sensor
(HO2S) located in the exhaust system. The HO2S tells
the PCM how much oxygen is in the exhaust gas. The
PCM changes the air/fuel ratio to the engine by controlling
the amount of time that fuel injector is “ON.” The best
mixture to minimize exhaust emissions is 14.7 parts of air
to 1 part of gasoline by weight, which allows the catalytic
converter to operate most efficiently. Because of the

6E–343 ENGINE DRIVEABILITY AND EMISSIONS
constant measuring and adjusting of the air/fuel ratio, the
fuel injection system is called a “closed loop” system.
The PCM monitors signals from several sensors in order
to determine the fuel needs of the engine. Fuel is
delivered under one of several conditions called “modes.”
All modes are controlled by the PCM.
Fuel Pressure Regulator
The fuel pressure regulator is a diaphragm-operated
relief valve mounted on the fuel rail with fuel pump
pressure on one side and manifold pressure on the other
side. The fuel pressure regulator maintains the fuel
pressure available to the injector at three times
barometric pressure adjusted for engine load. It may be
serviced separate.
If the pressure is too low, poor performance and a DTC
P0131, DTC P0151,DTC P0171 or DTC P1171 will be the
result. If the pressure is too high, excessive odor and/or a
DTC P0132, DTC P0152,DTC P0172 or DTC P0175 will
be the result. Refer to
Fuel System Diagnosis for
information on diagnosing fuel pressure conditions.
0011
Fuel Pump Electrical Circuit
When the key is first turned “ON,” the PCM energizes the
fuel pump relay for two seconds to build up the fuel
pressure quickly. If the engine is not started within two
seconds, the PCM shuts the fuel pump off and waits until
the engine is cranked. When the engine is cranked and
the 58 X crankshaft position signal has been detected by
the PCM, the PCM supplies 12 volts to the fuel pump relay
to energize the electric in-tank fuel pump.
An inoperative fuel pump will cause a “no-start” condition.
A fuel pump which does not provide enough pressure will
result in poor performance.
Fuel Rail
The fuel rail is mounted to the top of the engine and
distributes fuel to the individual injectors. Fuel is
delivered to the fuel inlet tube of the fuel rail by the fuel
lines. The fuel goes through the fuel rail to the fuel
pressure regulator. The fuel pressure regulator maintainsa constant fuel pressure at the injectors. Remaining fuel
is then returned to the fuel tank.
055RW009
Idle Air Control (IAC) Valve
The purpose of the idle air control (IAC) valve is to control
engine idle speed, while preventing stalls due to changes
in engine load. The IAC valve, mounted in the throttle
body, controls bypass air around the throttle plate. By
moving the conical valve (pintle) in (to decrease air flow)
or out (to increase air flow), a controlled amount of air can
move around the throttle plate. If the RPM is too low, the
PCM will retract the IAC pintle, resulting in more air
moving past the throttle plate to increase the RPM. If the
RPM is too high, the PCM will extend the IAC pintle,
allowing less air to move past the throttle plate,
decreasing the RPM.
The IAC pintle valve moves in small steps called counts.
During idle, the proper position of the IAC pintle is
calculated by the PCM based on battery voltage, coolant
temperature, engine load, and engine RPM. If the RPM
drops below a specified value, and the throttle plate is
closed, the PCM senses a near-stall condition. The PCM
will then calculate a new IAC pintle valve position to
prevent stalls.
If the IAC valve is disconnected and reconnected with the
engine running, the idle RPM will be wrong. In this case,
the IAC must be reset. The IAC resets when the key is
cycled “ON” then “OFF.” When servicing the IAC, it
should only be disconnected or connected with the
ignition “OFF.”
The position of the IAC pintle valve affects engine start-up
and the idle characteristics of the vehicle. If the IAC pintle
is fully open, too much air will be allowed into the manifold.
This results in high idle speed, along with possible hard
starting and a lean air/fuel ratio. DTC P0507 or DTC
P1509 may set. If the IAC pintle is stuck closed, too little
air will be allowed in the manifold. This results in a low idle
speed, along with possible hard starting and a rich air/fuel
ratio. DTC P0506 or DTC P1508 may set. If the IAC
pintle is stuck part-way open, the idle may be high or low
and will not respond to changes in the engine load.

6E–344
ENGINE DRIVEABILITY AND EMISSIONS
0006
Run Mode
The run mode has the following two conditions:
Open loop
Closed loop
When the engine is first started the system is in “open
loop” operation. In “open loop,” the PCM ignores the
signal from the heated oxygen sensor (HO2S). It
calculates the air/fuel ratio based on inputs from the TP,
ECT, and MAF sensors.
The system remains in “open loop” until the following
conditions are met:
The HO2S has a varying voltage output showing that
it is hot enough to operate properly (this depends on
temperature).
The ECT has reached a specified temperature.
A specific amount of time has elapsed since starting
the engine.
Engine speed has been greater than a specified RPM
since start-up.
The specific values for the above conditions vary with
different engines and are stored in the programmable
read only memory (PROM). When these conditions are
met, the system enters “closed loop” operation. In
“closed loop,” the PCM calculates the air/fuel ratio
(injector on-time) based on the signal from the HO2S.
This allows the air/fuel ratio to stay very close to 14.7:1.
Starting Mode
When the ignition is first turned “ON,” the PCM energizes
the fuel pump relay for two seconds to allow the fuel pump
to build up pressure. The PCM then checks the engine
coolant temperature (ECT) sensor and the throttle
position (TP) sensor to determine the proper air/fuel ratio
for starting.
The PCM controls the amount of fuel delivered in the
starting mode by adjusting how long the fuel injectors are
energized by pulsing the injectors for very short times.
Throttle Body Unit
The throttle body has a throttle plate to control the amount
of air delivered to the engine. The TP sensor and IAC
valve are also mounted on the throttle body. Vacuum
ports located behind the throttle plate provide the vacuum
signals needed by various components.
Engine coolant is directed through a coolant cavity in the
throttle body to warm the throttle valve and to prevent
icing.
0019
General Description (Electronic
Ignition System)
Camshaft Position (CMP) Sensor
As the camshaft sprocket turns, a magnet in the sprocket
activates the Hall-effect switch in the CMP sensor. When
the Hall-effect switch is activated, it grounds the signal
line to the PCM, pulling the camshaft position sensor
signal circuit’s applied voltage low. This is a CMP signal.
The CMP signals is created as piston #1 is approximately
25
after top dead counter on the power stroke. If the
correct CMP signal is not received by the PCM, DTC
P0341 will be set.

6A – 10 ENGINE MECHANICAL
8. Check the engine oil level and replenish to the
specified level if required.
9. Start the engine and check for oil leakage from the
main oil filter.
FUEL SYSTEM
Fuel filter
Replacement Procedure
1. Loosen the used fuel filter by turning it
counterclockwise with the filter wrench.
Filter Wrench : 5-8840-0203-0
2. Clean the filter cover fitting faces.
This will allow the new fuel filter to seat properly.
3. Apply a light coat of engine oil to the O-ring.
4. Turn the fuel filter until the sealing face comes in
contact with the O-ring.
5. Turn the fuel filter with a filter wrench 2/3 of a turn
until sealed.
Filter Wrench: 5-8840-0203-0Legend
(1) Priming pump
6. Operate the priming pump until the air is discharged
completely from fuel system.
NOTE: The use of an Isuzu genuine fuel filter is
strongly recommended.
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator
reserve tank as necessary.
If the coolant level falls below the “‘MIN” line, carefully
check the cooling system for leakage. Then add
enough coolant to bring the level up to the “MAX” line.
NOTE: Do not overfill the reserve tank.
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1
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