lock OPEL FRONTERA 1998 Workshop Manual

6E–170
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1655 (Flash DTC 17)
Thermo Relay Circuit Open/Short
060RW130
Circuit Description
The thermo relay circuit receives current through air con
10A fuse from the battery, current flowing in the order of
the thermo relay and thermo SW.
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 P1655 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–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–183 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Rough, Unstable, or Incorrect Idle, Stalling Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Engine runs unevenly at idle. If severe, the engine or
vehicle may shake. Engine idle speed may vary in
RPM. Either condition may be severe enough to stall
the engine.
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?
—Go to Step 6Go to Step 3
3Was a visual/physical check performed?
—Go to Step 4
Go to Visual/
Physical
Check
41. Check the ECM grounds for cleanliness, tightness
and proper routing. 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 5
51. Check for incorrect idle speed. Ensure that the
following conditions are present:
The engine is fully warm.
The accessories are “OFF.”
2. Using a Tech 2, monitor the AP position.
Is the AP position within the specified values?
0%Go to Step 10Go to Step 9
61. Visually/physically inspect for the following
conditions:
Restricted air intake system. Check for a
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
71. Injector Test
Operate the each injector by Tech 2 with the
ignition “ON” and check if the working noise
confirm.
2. If a problem is found, check the harness or replace
the injector.
Is the action complete?
—Verify repairGo to Step 8
81. Check the transmission range switch circuit. Use a
Tech 2 and be sure the Tech 2 indicates that the
vehicle is in drive with the gear selector in drive or
overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary (Refer to
Automatic Transmission Diagnosis).
Was a problem found?
—Verify repairGo to Step 9

6E–189 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Cuts Out, Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Steady pulsation or jerking that follows engine speed;
usually more pronounced as engine load increases.
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?
—Go to Step 7Go to Step 3
3Was a visual/physical check performed?
—Go to Step 4
Go to Visual/
Physical
Check
41. Check the ECM grounds for clearness, tightness
and proper routing. 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 5
51. Check for incorrect idle speed. Ensure that the
following conditions are present:
The engine is fully warm.
The accessories are “off.”
2. Using a Tech 2, monitor the AP position.
Is the AP position within the specified values?
0%Go to Step 6Go to Step 7
61. Visually/physically inspect for the following
conditions:
Restricted air intake system. Check for a
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
Check the Throttle body.
Large vacuum leak. Check for a condition that
causes a large vacuum leak, such as an
incorrectly installed or faulty VSV or brake
booster hose disconnected .
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
7Using a Tech 2, monitor the AP angle with the engine
idling.
Is the AP angle at the specified value and steady?
0%Go to Step 8
Refer to DTC
P0123
for
further
diagnosis
81. Check the transmission range switch circuit. Use a
Tech 2 and be sure the Tech 2 indicates that the
vehicle is in drive with the gear selector in drive or
overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary.
Was a problem found?
—Verify repairGo to Step 9

6E–202
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Crankshaft Position (CKP)
Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the under cover.
035RW091
3. Disconnect the electrical connector to the CKP
sensor.
4. Remove one bolt and the CKP sensor from the left
side of the engine block.
NOTE: Use caution to avoid any hot oil that might drip
out.
035RW090
Inspection Procedure
1. Inspect the sensor O-ring for cracks or leaks.
2. Replace the O-ring if it is worn or damaged.
3. Lubricate the new O-ring with engine oil.
4. Install the lubricated O-ring.
Installation Procedure
1. Install the CKP sensor in the engine block.
2. Install the CKP sensor mounting bolt.
Tighten
Tighten the mounting bolt to 9 Nꞏm (78 lb in.).
035RW090
3. Connect the electrical connector to the CKP sensor.
4. Install the under cover.
035RW091
5. Connect the negative battery cable.

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.

6F – 2 ENGINE EXHAUST
GENERAL DESCRIPTION
150RW070
When inspecting or replacing exhaust system
components, make sure there is adequate clearance
from all points on the underbody to prevent overheating
of the floor pan and possible damage to the passenger
compartment insulation and trim materials.
Check complete exhaust system and nearby body
areas and rear compartment lid for broken, damaged,
missing or mispositioned parts, open seams, holes
loose connections or other deterioration which could
permit exhaust fumes to seep into the rear
compartment or passenger compartment. Dust or water
in the rear compartment may be an indication of a
problem in one of these areas. Any faulty areas should
be corrected immediately.HANGERS
Various types of hangers are used to support exhaust
system(s). These include conventional rubber straps,
rubber rings, and rubber blocks.
The installation of exhaust system supports is very
important, as improperly installed supports can cause
annoying vibrations which can be difficult to diagnose.
GASKET
The gasket must be replaced whenever a new exhaust
pipe, muffler or exhaust throttle is installed.

ENGINE LUBRICATION 6G – 5
OIL PUMP
REMOVAL
1. Remove battery ground cable.
2 Raise the vehicle and support with suitable safety
stand.
3. Drain engine oil.
4. Remove flywheel assembly.
5. Remove rear plate (For A/T) or flywheel housing
(For MT).
6. Remove first oil pump assembly from cylinder block
and second oil pump assembly from crank case.
INSPECTION AND REPAIR
1. Inspect flaws and/or wear on the teeth surface.
2. Inspect abnormal wear journal on the gear and in
the drive spline.
3. If problem is found during inspection, the worn parts
must be replaced.
INSTALLATION
1. Install first oil pump.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
2. Install second oil pump.
Torque: 20 Nꞏm (2ꞏ0 kg.m / 14.5 lb ft)
2
1
5
6
3
4
Legend
(1) Flywheel
(2) Rear Plate
(3) First Oil Pump(4) Second Oil Pump
(5) O-ring (For 1st oil pump)
(6) O-ring (For 2nd oil pump)
012RW097