sensor OPEL FRONTERA 1998 Workshop Manual

6E–39 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Engine Control Module ECM
Diagnosis
To read and clear diagnostic trouble codes, use a Tech 2.
IMPORTANT:Use of a Tech 2 is recommended to clear
diagnostic trouble codes from the ECM memory.
Diagnostic trouble codes can also be cleared by turning
the ignition “OFF” and disconnecting the battery power
from the ECM for 30 seconds. Turning off the ignition and
disconnecting the battery power from the ECM will cause
all diagnostic information in the ECM memory to be
cleared. Therefore, all the diagnostic tests will have to be
re-run.
Since the ECM can have a failure which may affect only
one circuit, following the diagnostic procedures in this
section will determine which circuit has a problem and
where it is.
If a diagnostic chart indicates that the ECM connections
or the ECM is the cause of a problem, and the ECM is
replaced, but this does not correct the problem, one of the
following may be the reason:
There is a problem with the ECM terminal
connections. The terminals may have to be removed
from the connector in order to check them properly.
The problem is intermittent. This means that the
problem is not present at the time the system is being
checked. In this case, refer to the
Symptoms portion
of the manual and make a careful physical inspection
of all components and wiring associated with the
affected system.
There is a shorted solenoid, relay coil, or harness.
Solenoids and relays are turned “ON” and “OFF” by
the ECM using internal electronic switches called
drivers. A shorted solenoid, relay coil, or harness will
not damage the ECM but will cause the solenoid or
relay to be inoperative.
Multiple ECM Information Sensor
DTCS Set
Circuit Description
The Engine Control Module ECM monitors various
sensors to determine the engine operating conditions.
The ECM controls fuel delivery, spark advance,
transmission operation, and emission control device
operation based on the sensor inputs.
The ECM provides a sensor ground to all of the sensors.
The ECM applies 5 volts through a pull-up resistor, and
determines the status of the following sensors by
monitoring the voltage present between the 5-volt supply
and the resistor:
The fuel temperature (FT) sensor
The engine coolant temperature (ECT) sensor
The Intake air temperature (IAT) sensor
The ECM provides the following sensors with a 5-volt
reference and a sensor ground signal:
The Intake throttle position sensor
The manifold absolute pressure sensor
The rail pressure sensor
The accelerator position sensor
The oil temperature sensor
The camshaft position sensor
The crankshaft position sensor
The EGR pressure sensor
The ECM monitors the signals from these sensors in
order to determine their operating status.
Diagnostic Aids
IMPORTANT:Be sure to inspect ECM and engine
grounds for being secure and clean.
A short to voltage in one of the sensor input circuits may
cause one or more of the following DTCs to be set:
P0337
P0342
P1193
P1404
P1405
P1488
IMPORTANT:If a sensor input circuit has been shorted
to voltage, ensure that the sensor is not damaged. A
damaged sensor will continue to indicate a high or low
voltage after the affected circuit has been repaired. If the
sensor has been damaged, replace it.
An open in the sensor ground circuit between the ECM
and the splice will cause one or more of the following
DTCs to be set:
P0337
P0342
P0117
A short to ground in the 5-volt reference A or B circuit will
cause one or more of the following DTCs to be set:
P0112
P0117
P0182
P0197
An open in the 5-volt reference circuit A, between the
ECM and the splice will cause one or more of the following
DTCs to be set:
P0107
P0405
P1194
P0122
An open in the 5-volt reference circuit B, between the
ECM and the splice will cause one or more of the following
DTCs to be set:
P1485
Check for the following conditions:
Poor connection at ECM. Inspect the harness
connectors for backed-out terminals, improper
mating, broken locks, improperly formed or damage
terminals, and a poor terminal-to-wire connection.
Damaged harness. Inspect the wiring harness for
damage. If the harness is not damaged, observe an
affected sensor’s displayed value on the Tech 2 with
the ignition “ON” and the engine “OFF” while you
move the connectors and the wiring harnesses
related to the following sensors:
ECT Sensor

6E–40
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
MAP Sensor
CMP Sensor
CKP Sensor
EGR Pressure Sensor
EGR VSV
RPCV
IAT Sensor
Intake Throttle Motor
Fuel Temperature Sensor
Oil Temperature Sensor
Rail Pressure Sensor
Multiple ECM Information Sensor DTCs Set
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
21. Turn the ignition “OFF,” disconnect the ECM.
2. Turn the ignition “ON,” check the 5 volt reference D
circuit for the following conditions:
D poor connection at the ECM.
An open between the ECM connector and the
splice.
D short to ground.
D short to voltage.
Is there an open or short?
—Go to Step 3Go to Step 4
3Repair the open or short.
Is the action complete?
—Verify repair—
4Check the sensor ground circuit for the following
conditions:
A poor connection at the ECM or the affected
sensors.
An open between the ECM connector and the
affected sensors.
Is there an open or a poor connection?
—Go to Step 5Go to Step 6
5Repair the open or the poor connection.
Is the action complete?
—Verify repairGo to Step 6
6Replace the ECM (Refer to the Data Programming in
Case of ECM change).
Is the action complete?
—
Go to OBD
System
Check
—

6E–41 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
EGR (Exhaust Gas Recirculation)
Diagnosis
A diagnosis of the EGR system is covered by DTC
P1403.
EGR VSV circuit diagnosis is covered by DTC P1404.
EGR pressure sensor diagnosis is covered by DTC
P405 and/or P406.
EGR EVRV circuit diagnosis is covered by DTC
P1405. Refer to the DTC charts.
Tech 2 Data Definitions and Ranges
A/C CLUTCH–Tech 2 Displays ON or OFF–
Indicates whether the A/C has commanded the A/C
clutch ON.
MAP kPa — Tech 2 Range 10-105 kPa/0.00-5.00
Vo l t s —
The manifold absolute pressure reading is determined
from the MAP sensor signal monitored during key up and
wide open throttle (WOT) conditions. The manifold
absolute pressure is used to compensate for altitude
differences and is normally displayed around “61-104”
depending on altitude and manifold absolute pressure.
CMP ACT. COUNTER –Cam Position
DESIRED IDLE — Tech 2 Range 0-3187 RPM —
The idle speed that the ECM is commanding. The ECM
will compensate for various engine loads based on engine
coolant temperature, to keep the engine at the desired
speed.
ECT — (Engine Coolant Temperature) Tech 2
Range –40
C to 151C (–40F to 304F) —
The engine coolant temperature (ECT) is mounted in the
coolant stream and sends engine temperature
information to the ECM. The ECM applies 5 volts to the
ECT sensor circuit. The sensor is a thermistor which
changes internal resistance as temperature changes.
When the sensor is cold (high resistance), the ECM
monitors a high signal voltage and interprets that as a cold
engine. As the sensor warms (decreasing resistance),
the voltage signal will decrease and the ECM will interpret
the lower voltage as a warm engine.
ENGINE RUN TIME — Tech 2 Range
00:00:00-99:99:99 Hrs:Min:Sec —
Indicates the time elapsed since the engine was started.
If the engine is stopped, engine run time will be reset to
00:00:00.
ENGINE SPEED — Range 0-9999 RPM —
Engine speed is computed by the ECM from the 57X
reference input. It should remain close to desired idle
under various engine loads with engine idling.Air Intake Valve meter POSITION — Tech 2 Range
0-100 % —
IAT (INTAKE AIR TEMPERATURE)— Tech 2 Range
–40
C to 151C (–40F to 304F) —
The ECM converts the resistance of the intake air
temperature sensor to degrees. Intake air temperature
(IAT) is used by the ECM to adjust fuel delivery and spark
timing according to incoming air density.
MAP — Tech 2 Range 10-105 kPa (0.00-4.97 Volts)—
The manifold absolute pressure (MAP) sensor measures
the change in the boost pressure.
MIL — Tech 2 Displays ON or OFF —
Indicates the ECM commanded state of the malfunction
indicator lamp.
AP — Tech 2 Range 0%-100% —
AP (Accelerator position) angle is computed by the ECM
from the AP sensor voltage. AP angle should display
“0%” at idle and “100%” at wide open throttle.
AP SENSOR — Tech 2 Range 0.00-5.00 Volts —
The voltage being monitored by the ECM on the AP
sensor signal circuit.
VEHICLE SPEED—Tech 2 Range 0-255 km/h (0-155
mph)–
The vehicle speed sensor signal is converted into km/h
and mph for display.
Typical Scan Data Values
Use the Typical Scan Data Values Table only after the
On-Board Diagnostic System Check has been
completed, no DTC(s) were noted, and you have
determined that the on-board diagnostics are functioning
properly. Tech 2 values from a properly-running engine
may be used for comparison with the engine you are
diagnosing. The typical scan data values represent
values that would be seen on a normally-running engine.
NOTE: A Tech 2 that displays faulty data should not be
used, and the problem should be reported to the Tech 2
manufacturer. Use of a faulty Tech 2 can result in
misdiagnosis and unnecessary replacement of parts.
Only the parameters listed below are referred to in this
service manual for use in diagnosis. For further
information on using the Tech 2 to diagnose the ECM and
related sensors, refer to the applicable reference section
listed below. If all values are within the typical range
described below, refer to the
Symptoms section for
diagnosis.
Test Conditions
Engine running, lower radiator hose hot, transmission in
park or neutral, accessaries off, brake not applied and air
conditioning off.

6E–42
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
4JX1-TC Engine (Automatic and Manual Transmission)
Te c h 2
Parameter
Data ListUnits
DisplayedTy p i c a l D a t a
Values (IDLE)Typical Data
Va l u e s
(2500 RPM)Refer To
Battery VoltageEngineVo l t s12.5 14.513 15General Description
Ignition StatusEngineOn/OffOnOnGeneral Description
Ignition Relay2EngineOn/OffOnOnGeneral Description
Idle SwitchEngineInactive/
Active——DTC P0510, P1510
Manifold
Absolute
PressureEngineKPa96 106110 150General Description
DTC P0107, P0108
Rail Oil
PressureEngineMPa3.5 54.5 10General Description
DTC P0192, P0193
Desired Rail Oil
PressureEngineMPa4 55 9General Description
DTC P0192, P0193
Fuel
TemperatureEngineC (F)75 8575 85DTC P0182, P0183
Quick Warming
SwitchEngineOn/OffOffOffDTC P0380
Thermo RelayEngineOn/Off——DTC P1655
Actual EGR
PressureEngineKPa58 60M/T 63 66
A/T 95
105
DTC P0405, P0406
Barometric
PressureEngineKPa98 10298 102General Description
Relative EGR
PressureEngineKPa–38 –45M/T –34 –37
A/T 0General Description
Desired EGR
PressureEngineKPa–43 –40M/T 36
A/T 0General Description
Brake SwitchEngineInactive/
Active——DTC P1588
GearEngine————
Vehicle SpeedEngineKm/h00Transmission Diagnosis
Rail Pressure
Control ValveEngine%17 2218 27DTC P1193
EGR StatusEngineDisable/
EnableEnableM/T Enable
A/T DisableGeneral Description
EGR Switching
Va l v eEngineOn/Off——General Description
Throttle Motor
Position SensorEngineVo l t s3.1 3.90.2 0.9DTC P1485, P1486,
P1487
Throttle Motor
PositionEngineSteps
0 1.00 1.0
DTC P1488
Delirered Fuel
QuantityEnginemm 3/st
6 106 12
General Description
Injector StatusEngineDisable/
EnableEnableEnableDTC P0201, P0202,
P0203, P0204, General
Description
Injector Pulse
WidthEnginems0.9 1.250.7 1.1General Description
Injector Start
OffsetEngineCA——General Description

6E–48
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Malfunction Indicator Lamp (MIL) “ON” Steady
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
21. Ignition “OFF,” disconnect ECM.
2. Ignition “ON,” observe the MIL (CHECK ENGINE
lamp).
Is the MIL “ON?”
—Go to Step 3Go to Step 5
31. Ignition “OFF,” disconnect the instrument panel
cluster.
2. Check the MIL driver circuit between the ECM and
the instrument panel cluster for a short to ground.
3. If a problem is found, repair as necessary.
Was the MIL driver circuit shorted to ground?
—
Go to OBD
System
Check
Go to Step 4
4Replace the instrument panel cluster.
Is the action complete?
—
Go to OBD
System
Check
—
51. Ignition “OFF,” reconnect the ECM.
2. Ignition “ON,” reprogram the ECM. Refer to
On-Vehicle Service in Engine Control Module and
Sensor
for procedures.
3. Using the Tech 2 output controls function, select
MIL dash lamp control and command the MIL
“OFF.”
Did the MIL turn “OFF?”
—
Go to OBD
System
Check
Go to Step 6
6Replace the ECM (Refer to the Data Programming in
Case of ECM change).
Is the action complete?
—
Go to OBD
System
Check
—

6E–49 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Engine Cranks But Will Not Run
Circuit Description
In this type of injector system, the Engine Control Module
(ECM) triggers the correct driver inside the injector, which
then triggers the correct injector based on the 57X signal
received from the crankshaft position sensor (CKP).
During crank, the ECM monitors the CKP 57X signal. The
CKP signal is used to determine which cylinder will fire
first. After the CKP 57X signal has been processed by the
ECM, it will command all four injectors to allow a priming
shot of fuel for all the cylinders. After the priming, the
injectors are left “OFF” during the next four 57X reference
pulses from the CKP. This allows each cylinder a chance
to use the fuel from the priming shot. During this waiting
period, a camshaft position (CMP) signal pulse will have
been received by the ECM. The CMP signal allows the
ECM to operate the injectors sequentially based on
camshaft position. If the camshaft position signal is not
present at start-up, the ECM will begin sequential fuel
delivery with a 1-in-4 chance that fuel delivery is correct.
The engine will run without a CMP signal, but will set a
DTC code.
Diagnostic Aids
An intermittent problem may be caused by a poor
connection, rubbed-through wire insulation or a wirebroken inside the insulation. Check for the following
items:
Poor connection or damaged harness – Inspect the
ECM harness and connectors for improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal-to-wore connection, and
damaged harness.
Faulty engine coolant temperature sensor – Using a
Tech 2, compare engine coolant temperature with
manifold air temperature on a completely cool engine.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
4. An obvious cause of low fuel pressure would be an
empty fuel tank.
5. The engine will easily start and run if a few injectors
are disabled. It is not necessary to test all injectors
at this time since this step is only a test to verify that
all of the injectors have not been disabled by fuel
contamination.
8.If there is an open or shorted driver circuit, DTCs
0201-0204 should be set.
Engine Cranks But Will Not Run
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 15 A injector fuse, the 15 A engine device
fuse, and the 15A ECM fuse.
Was a fuse blown?
—Go to Step 3Go to Step 4
3Check for a short to ground and replace the fuse.
Is the action complete?
—Verify repair—
4Is fuel tank empty?
—
Fill the fuel
tank
Go to Step 5
5Is the right fuel using?
—Go to Step 6
Replace the
fuel
6Is the right engine oil using?
—Go to Step 7
Replace the
engine oil
7Using the Tech–2.
Is DTC P0192 or P0193 set? (Check rail pressure
system)
—
Go to DTC
P0192 or
DTC P0193
Go to Step 8
8Using the Tech–2.
Is DTC P0201 – P0204 set? (Check inject circuit fault)
—
Go to DTC
P0201 –
P0204
Go to Step 9
9Using the Tech–2.
Is DTC P1657 set? (Check ECM Main relay)
—
Go to DTC
P1657
Go to Step 10

6E–50
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Engine Cranks But Will Not Run
StepNo Ye s Va l u e ( s ) Action
10Refer to Engine Mechanical Diagnosis to diagnose the
following conditions:
Faulty camshaft drive belts
Leaking or sticky valves or rings
Excessive valve deposits
Weak valve springs
Incorrect valve timing
Leaking head gasket
Is the action complete?
—Verify repairGo to Step 11
11Observe the “Engine Speed” data display on the Tech 2
while cranking the engine.
Is the engine RPM indicated? (If the Tech 2 is normally
powered from the cigarette lighter socket, and if the
Tech 2 display goes blank while cranking the engine, it
will be necessary to power the Tech 2 directly from the
vehicle battery.)
—Go to Step 12Go to Step 17
121. At the ECM (female) side of the connector
mentioned in step, connect a test light between the
ignition + terminal and one of the injector driver
circuits at the same connector.
2. Ignition “ON.”
3. Observe the test light, and repeat the test for each
injector driver circuit by oscilloscope.
Did the test light stay on when checking any of the 4
injector driver circuits?
—Go to Step 13Go to Step 15
131. Ignition “OFF,” disconnect the ECM.
2. Ignition “ON,” observe the test light.
Is the test light “ON?”
—Go to Step 14Go to Step 16
14Locate and repair the short to ground in the injector
driver circuit.
Is the action complete?
—Verify repair—
15Check for an open injector driver circuit.
Was a problem found?
—Verify repairGo to Step 16
16Replace the ECM (Refer to the Data Programming in
Case of ECM change).
Is the action complete?
—Verify repair—
171. Raise the vehicle and disconnect the CKP sensor
harness.
2. Ignition “ON.”
3. With a test light to ground, probe the harness
ignition feed terminal.
Did the light illuminate?
—Go to Step 19Go to Step 18
18Check the ignition feed wire between the sensor and
the ECM for a short to ground or open circuit.
Is the action complete?
—Verify repair—

6E–51 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Engine Cranks But Will Not Run
StepNo Ye s Va l u e ( s ) Action
191. Ignition “ON.”
2. At the CKP harness connector, connect a test light
between the ignition and ground terminals.
Did the light illuminate?
—Go to Step 21Go to Step 20
20Check the sensor ground circuit for an open or short to
voltage.
Is the action complete?
—Verify repair—
21Check the signal circuit between the sensor and the
ECM for a short to ground, short to voltage, or an open.
Was a problem found?
—Verify repairGo to Step 22
22Replace the CKP sensor.
Is the action complete?
—Verify repairGo to Step 16

6E–54
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
ECM Diagnostic Trouble Codes
The following table lists the diagnostic trouble codes
supported a Tech 2 and to flash.If any DTCs not listedhere are displayed by a Tech 2, the Tech 2 data may be
faulty; notify the Tech 2 manufacturer of any DTCs
displayed that are not included in the following table.
ECM Diagnostic Trouble Codes
DTC
using a
Te c h 2
Flash DTCDescriptionMIL
P010734MAP Sensor Low VoltageON
P010834MAP Sensor High VoltageON
P011223Intake Air temp Sensor Low VoltageON
P011323Intake Air temp Sensor High VoltageON
P011714Engine Coolant Temp Sensor Low VoltageON
P011814Engine Coolant Temp Sensor High VoltageON
P012133Accel Position Sensor RationalityON
P012221Accel Position Sensor Low VoltageON
P012321Accel Position Sensor High VoltageON
P018215Fuel Temp Sensor Low VoltageON
P018315Fuel Temp Sensor High VoltageON
P019263Rail Pressure Sensor Low VoltageON
P019363Rail Pressure Sensor High VoltageON
P119364RPCV Circuit Open/Short—
P119461Rail Pressure System Low VoltageON
P119561Rail Pressure System High VoltageON
P119662Rail Pressure System High WarningON
P019716Oil Temp sensor Low VoltageON
P019816Oil Temp sensor High VoltageON
P020151Injector #1 Circuit FaultON
P020252Injector #2 Circuit FaultON
P020353Injector #3 Circuit FaultON
P020454Injector #4 Circuit FaultON
P021722High Coolant Temp WarningON
P121736High Oil Temp WarningON
P021911Engine Over Speed WarningON
P033643Crank Position Sensor Out of SyncroON
P033743Crank Position Sensor No SignalON
P034141Cam Position Sensor Out of SyncroON
P034241Cam Position Sensor No SignalON
P038066Glow Relay Circuit Open/Short—
P038167Glow Lamp Circuit Open/Short—
P140332EGR EVRV Fault—
P140431EGR VSV Circuit—
P040526EGR Pressure Sensor Low VoltageON
P140537EGR EVRV Circuit Open/Short—
P040626EGR Pressure Sensor High VoltageON

6E–55 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
DTC
using a
Te c h 2Flash DTCDescriptionMIL
P047571EXH #1 VSV Circuit Open/Short—
P147571EXH #2 VSV Circuit Open/Short—
P148574Intake Throttle Position Sensor Low VoltageON
P148674Intake Throttle Position Sensor High VoltageON
P148773Intake Throttle System Circuit Open/ShortON
P148872Intake Throttle Motor Control Circuit Signal Gap—
P050224Vehicle Speed Sensor No SignalON
P051075Idle SW Malfunction, Open CircuitON
P151075Idle SW Malfunction, Short CircuitON
P056235System Voltage Too LowON
P156235System Voltage Too Low at CrankingON
P158725Brake SW Malfunction [B]—
P158825Brake SW Malfunction [A]ON
P060155ECM Checksum ErrorON
P162656Immobilizer No SignalON
P163156Immobilizer Wrong SignalON
P164856No Security Code EnteredON
P164956Immobilizer Function not ProgrammedON
P065077Check Engine Lamp Circuit Open/Short—
P065427Techometer Circuit Open/Short—
P165517Thermo Relay Circuit Open/Short—
P165776ECM Main Relay Circuit Open/Short—
P158947TransMission SW Circuit Open/Short—