fuel filter OPEL FRONTERA 1998 Repair Manual

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–185 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Poor Fuel Economy Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Fuel economy, as measured by an actual road test, is
noticeably lower than expected. Also, economy is
noticeably lower than it was on this vehicle at one time,
as previously shown by an actual road test. (Larger than
standard tires will cause odometer readings to be
incorrect, and that may cause fuel economy to appear
poor when it is actually normal.)
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
4Check owner’s driving habits.
Is the A/C “ON” full time (defroster mode “ON”)?
Are tires at the correct pressure?
Are excessively heavy loads being carried?
Is acceleration too much, too often?
Is engine oil correct?
Was a problem found?
—Go to Step 5Go to Step 6
5Review the items in Step 4 with the customer and
advise as necessary.
Is the action complete?
—System OK—
61. Visually/physically check: Vacuum hoses for splits,
kinks, and improper connections and routing as
shown on the “Vehicle Emission Control
Information” label.
2. If a problem is found, repair as necessary.
Was a repair required?
—Verify repairGo to Step 7
71. Remove and check the air filter element for dirt or for
restrictions. Refer to
Air Intake System.
2. Replace the air filter element if necessary.
Was a repair required?
—Verify repairGo to Step 8
81. Check for low engine coolant level. Refer to Engine
Cooling
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 9
91. Check for an incorrect or faulty engine thermostat.
Refer to
Engine Cooling.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 10
101. Check for low engine compression. Refer to Engine
Mechanical
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 11

6E–192
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Starting Difficulty In Case Fuel Doesn’t Come to Injector
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Engine is cranked, but not started for a long time. Steps
soon.
Was OBD System check performed?
—Go to Step 2
Go to OBD
System
Check
21. Perform a bulletin research.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found?
—Verify repairGo to Step 3
3Was a visual/physical check performed?
—Go to Step 4
Go to Visual/
Physical
Check
4Check fuel shortage. If short, replenish.
Was fuel short?
—
Ve r i f y
replenish
Go to Step 5
51. Check fuel pipeline for leak.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 6
61. Check fuel pipeline & filter for deformation &
clogging.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
71. Check fuel pump for damage.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 8
8Check the Injector test by Tech 2.
Does the working noise confirm?
—Go to Step 11Go to Step 9
91. Check the injector connector for damage.
2. Check the injector harness for damage.
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 10
10Replace the injector. (Refer to the injector group sign
programming)
Is the action complete?—Verify repair—
111. Indicate RPCV Data List by Tech 2 to check
operation. Perform RPCV test.
2. If a problem is found, replace RP sensor or RPCV
as necessary.
Was a problem found?
—Verify repairGo to Step 12

6E–213 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
3. Connect the electrical connector to the AP sensor.
035RW060
4. Connect the negative battery cable.
Fuel Filter Cap
General Description
The fuel filler cap includes a vacuum valve and a pressure
valve.
If high vacuum or high pressure occurs in the fuel tank,
each valve works to adjust the pressure in order to
prevent damage to the tank at the EGR valve.
TS23767
Inspection Procedure
NOTE: Replace the fuel filler cap with the same type of
filler cap that was originally installed on the vehicle.
Check the seal ring in the filler cap for any abnormality
and for seal condition.
Replace the filler cap if any abnormality is found.
Fuel Filter
Removal and Installation Procedure
Refer to the Engine fuel in the 4JX1 Engine section.
Fuel Gauge Unit
Removal Procedure
1. Disconnect the negative battery cable.
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank.
Tighten
Tighten the drain plug to 20 Nꞏm (14 lb ft.).
TS22907
4. Disconnect the wiring connector from the fuel gauge
unit.
TS23771
5. Remove the fuel gauge unit retaining screws.

6E–228
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
General Description (Air Induction)
Air Induction System
The air induction system filters contaminants from the
outside air, and directs the progress of the air as it is
drawn into the engine. A remote-mounted air cleaner
prevents dirt and debris in the air from entering the
engine. The air duct assembly routes filtered air to the
throttle body. Air enters the engine by to following steps:
1. Through the throttle body.
2. Into the intake manifold.
3. Through the cylinder head intake ports.
4. Into the cylinders.
General Description (Fuel Metering)
Deceleration Mode
The ECM reduces the amount of fuel injected when it
detects a decrease in the Accelerator position.
Fuel Injector
Fuel injector comprises the solenoid, hydraulic line, and
fuel line. Fuel injection is controlled by the continuity time
signal and continuity start timing signal from ECM to the
solenoid
ECM determines the running conditions of engine by
input signals such as engine speed. Accelerator throttle
valve opening, and engine coolant temperature, thereby
to send the solenoid the best suited signal to the engine
status. When current is carried to the solenoid, the
armature opens the poppet valve to alow high pressure oil
to run into the injector. Under the pressure of the oil, the
piston and plunger are depressed to compress the fuel in
the combustion chamber of the plunger. Specifically, the
pressure of the fuel compressed is increased by a piston
top/ plunger bottom area ratio over the pressure of high
pressure oil, thereby lifting the fuel nozzle end needle for
injecting fuel.
Fuel Metering System Components
The fuel metering system is made up of the following
parts:
The fuel injectors.
The intake throttle body.
The Accelerator position (AP) sensor
The ECM.
The crankshaft position (CKP) sensor.
The camshaft position (CMP) sensor.
Basic System Operation
Fuel is supplied through fuel filter to the fuel pump.
The fuel pump is installed to the oil pump, and fuel is
forced, through the fuel pump outlet, pipe and cylinder
head inside, into the fuel injector.
An orifice is provided at the rear fuel outlet of cylinder
head to control the pressure of oil.The injector is controlled by ECM which gives
opening/closing commands to the solenoid installed on
the top of the injector. Opening/closing operation of the
pressurized engine oil circuit of the injector controls fuel
injection quantity, fuel injection timing, etc.
A/C Clutch Diagnosis
A/C Request Signal
This signal tells the ECM when the A/C mode is selected
at the A/C control head. The ECM uses this to adjust the
idle speed.
Refer to
A/C Clutch Circuit Diagnosis for A/C wiring
diagrams and diagnosis for A/C electrical system.
General Description Exhaust Gas
Recirculation (EGR) System
EGR Purpose
The exhaust gas recirculation (EGR) system is use to
reduce emission levels of oxides of nitrogen (NOx). NOx
emission levels are caused by a high combustion
temperature. The EGR system lowers the NOx emission
levels by decreasing the combustion temperature.
The ECM uses information from the following sensors to
control EGR valve boost pressure.
ECT
ITP
Engine Speed
AP sensor

ENGINE LUBRICATION 6G – 3
To meet a newly adopted electronically controlled fuel
injection system using engine oil two oil pumps have
been provided to increase circulating oil capacity.
The first oil pump serves mainly to lubricate the engine
parts, while the second mainly serves the fuel injectors
and partially cools the pistons.
The oil cooler is provided on the first oil pump side and
uses engine coolant.
OIL FLOW
Legend
(1) Oil Pump
(2) Regulator Valve
(3) Oil Cooler
(4) Oil Filter Relief Valve
(5) Full Flow Filter
(6) Oil Cooler Relief Valve
(7) Gallery
OIL PUMP SPECIFICATIONS

OIL FILTER SPECIFICATIONS
Legend
(1) Oil cooler assembly
(2) Oil filter assembly (25) Edge Filter
(26) Edge Filter
(27) High Pressure Oil Pump Assembly
(28) To Oil Pan
(29) Pressure Control Valve(30) To Oil Pan
(31) Turbocharger
(32) Oil Gallery
(33) Timing Gear Train
17 65 4
3
2
050RW010
For Europe1
2
050R200001

D08RW737
BRAKE EHCU:ELECTRONIC HYDRAULIC CONTROL UNIT
SEDIMENTER 4WD
BRAKE
FLUID
SWPARKING
BRAKE
SW
18
19
4WD
CONTROL
UNIT(19)
FRT AXLE
SW(2)4WD
SW(1)0.5
LG
0.5
LG 0.5
LG 0.5
LGI-9
H-2723
7
2 0.5
V
0.3
V0.5
B/P
0.85
B/P
0.5
B0.5
B/P0.5
B/P I-9
H-9
H-674
1
8 9
213
1
FENDER-RH0.5
B/PI-9
H-16
C-15
C-39 C-15FUEL
FILTER
SW
0.5
B1
2
FENDER-L HC-16 C-67
VACUUM
SW
1
C-68H-26
B-27
METER

D08RW914
H
SEAT
BELT
SW
BODY-LH
B-18
BODY-CTRBODY-RH
B-2
2
11 0.3
L
0.5
L
2.0
B 2.0
B 2.0
B 0.5
BI-9
B-24 H-25
1
B-24
SEAT
BELT
B-262
BRAKE EHCU:ELECTRONIC HYDRAULIC CONTROL UNIT
SEDIMENTER 4WD
BRAKE
FLUID
SWPARKING
BRAKE
SW
18
22
4WD
CONTROL
UNIT(19)
FRT AXLE
SW(2)4WD
SW(1) SDM
(20)0.5
LG
0.5
LG 0.5
LG 0.85
LGI-9
H-2523
20
2 0.5
V
0.3
V0.5
B/P
0.85
B/P
0.5
B0.5
B/P0.5
B/P I-9
H-9
H-674
1
3 17
215
1
FENDER-LH0.5
B/PI-9
H-9
C-15
C-16 C-15FUEL
FILTER
SW
0.5
B1
2
FENDER-L HC-16 C-67
VACUUM
SW
1
C-68H-25
B-27
METER

8J–4EXTERIOR/INTERIOR TRIM
Consoles
Consoles and Associated Parts
This illustration is based on RHD
745RW009
Legend
(1) Shift Knob (M/T) / Transfer Knob (A/T)
(2) Assist Grip
(3) Fuel Filler Lid Opener(4) Center Console Assembly
(5) Front Seat Assembly (RH)
(6) Front Console Assembly
Removal
1. Disconnect the battery ground cable.
2. Remove the shift knob (M/T) / transfer knob (A/T).
3. Remove the front console assembly.
Remove four fixing screws and disconnect the
switch connectors.
4. Remove the front seat assembly(RH).
Refer to the Front Seat Assembly removal steps in
Seats section.
5. Remove the assist grip.
Remove three bolts.
6. Remove the fuel filler lid opener.
Remove the fuel filter lid opener(1) and disconnect
the cable(2).
686RW007

6A–3
ENGINE MECHANICAL
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick–up unit.
The 12–volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die–cast casting
for 75
V–type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent–roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V–type design. The ports are cross–flow
type.
Va l v e Tr a i n
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast–iron. Pins and
journals are graded for correct size selection for their
bearing.
Engine Lubrication
The oil discharged by a trochoid–type oil pump driven by
the crankshaft is fed through full–flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.