1998 OPEL FRONTERA ABS

6E–315 ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Install the O-ring backup on the fuel injector.
2. Install the new O-ring on the fuel injector.
3. Install the fuel injector on the fuel rail.
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4. Use new fuel injector retainer clips to retain the fuel
injector to the fuel rail.
5. Coat the end of the fuel injector with engine oil.
6. Install the fuel rail. Refer to
Fuel Rail.
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7. Install the upper intake manifold. Refer to Common
Chamber in Engine Mechanical.
8. Install the engine cover.
9. Connect the negative battery cable.
Fuel Pressure Regulator
Removal Procedure
CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when servicing
fuel lines or connections. Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before disconnecting the fittings. The
towels will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
NOTE: Compressed air must never be used to test or
clean a fuel pressure regulator, as damage to the fuel
pressure regulator may result.
NOTE: To prevent damage to the fuel pressure regulator,
do not immerse the pressure regulator in solvent.
1. Depressurize the fuel system. Refer to
Fuel Pressure
Relief Procedure
.
2. Disconnect the negative battery cable.
3. Remove the fuel pump relay. Refer to
Fuel Pump
Relay
.
4. Remove the pressure regulator hose from the fuel
pressure regulator.
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6E–317 ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Install the fuel pressure regulator attaching screw.
Tighten
Tighten the fuel pressure regulator attaching screw
to 3 Nꞏm (26 lb in.).
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2. Install the fuel pressure regulator on the fuel rail.
3. Install the two bolts to the protector that secures the
common chamber.
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4. Install the pressure regulator hose to the fuel
pressure regulator.
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5. Install the fuel pump relay. Refer to Fuel Pump Relay.
6. Connect the negative battery cable.
7. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel lines.
Fuel Metering System
Fuel Pressure Relief Procedure
CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when servicing
fuel lines or connections. Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before you disconnect the fittings. The
towels will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
1. Remove the fuel cap.

6E–320
ENGINE DRIVEABILITY AND EMISSIONS
IMPORTANT:An eight-digit identification number is
stamped on the side of the fuel rail. Refer to this number
when you service the fuel rail or when a replacement part
is required.
TS24022
Before removal, the fuel rail assembly may be cleaned
with a spray type engine cleaner. Follow the spray
package instructions. Do not immerse the fuel rails in
liquid cleaning solvent.
1. Depressurize the fuel system. Refer to Fuel Pressure
Relief Procedure in this Section.
2. Disconnect the negative battery cable.
3. Remove the engine cover.
4. Disconnect the accelerator pedal cable from throttle
body and cable bracket.
5. Disconnect the connectors from manifold absolute
pressure sensor, solenoid valve, electric vacuum
sensing valve.
6. Disconnect the vacuum hose on canister VSV and
positive crankcase ventilation hose.
7. Remove the common chamber. Refer to the common
chamber in Engine Mechanical.
1. Lift up carefully on the fuel injectors. Do not
separate the fuel injectors from the fuel rail.
2. If an injector becomes separated from the fuel
rail, the infector O-ring seals and the retainer clip
must be replaced.
3. Drain residual fuel into an approved container.
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8. If removal of the fuel pressure regulator is necessary,
refer to
Fuel Pressure Regulator.
9. If removal of the fuel injectors is necessary, refer to
Fuel Injectors.
Installation Procedure
1. If the fuel injectors were removed, install them. Refer
to
Fuel Injectors.
2. If the fuel pressure regulator was removed, install it.
Refer to
Fuel Pressure Regulator.
3. Install the common chamber. Refer to common
chamber in engine Mechanical.
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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–338
ENGINE DRIVEABILITY AND EMISSIONS
RPM. A failure in the MAF sensor or circuit will set DTC
P0101, DTC P0102, or DTC P0103.
0007
Manifold Absolute Pressure (MAP) Sensor
The manifold absolute pressure (MAP) sensor responds
to changes in intake manifold pressure (vacuum). The
MAP sensor signal voltage to the PCM varies from below
2 volts at idle (high vacuum) to above 4 volts with the
ignition ON, engine not running or at wide-open throttle
(low vacuum).
The MAP sensor is used to determine the following:
Manifold pressure changes while the linear EGR flow
test diagnostic is being run. Refer to
DTC P0401.
Engine vacuum level for other diagnostics.
Barometric pressure (BARO).
If the PCM detects a voltage that is lower than the
possible range of the MAP sensor, DTC P0107 will be set.
A signal voltage higher than the possible range of the
sensor will set DTC P0108. An intermittent low or high
voltage will set DTC P1107 or DTC P1106, respectively.
The PCM can detect a shifted MAP sensor. The PCM
compares the MAP sensor signal to a calculated MAP
based on throttle position and various engine load factors.
If the PCM detects a MAP signal that varies excessively
above or below the calculated value, DTC P0106 will set.
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Powertrain Control Module (PCM)
The powertrain control module (PCM) is located in the
passenger compartment below the center console. The
PCM controls the following:
Fuel metering system.
Transmission shifting (automatic transmission only).
Ignition timing.
On-board diagnostics for powertrain functions.
The PCM constantly observes the information from
various sensors. The PCM controls the systems that
affect vehicle performance. The PCM performs the
diagnostic function of the system. It can recognize
operational problems, alert the driver through the MIL
(Service Engine Soon lamp), and store diagnostic trouble
codes (DTCs). DTCs identify the problem areas to aid the
technician in making repairs.
This engine uses 2 different control modules:
IPCM-6KT for automatic transmission-equipped
vehicles.
ISFI-6 for manual transmission-equipped vehicles.
PCM Function
The PCM supplies either 5 or 12 volts to power various
sensors or switches. The power is supplied through
resistances in the PCM which are so high in value that a
test light will not light when connected to the circuit. In
some cases, even an ordinary shop voltmeter will not give
an accurate reading because its resistance is too low.
Therefore, a digital voltmeter with at least 10 megohms
input impedance is required to ensure accurate voltage
readings. Tool J 39200 meets this requirement. The PCM
controls output circuits such as the injectors, IAC, cooling
fan relays, etc., by controlling the ground or the power
feed circuit through transistors of following device.
Output Driver Module (ODM)

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

ENGINE MECHANICAL 6A – 11
Remove the radiator filler cap only when absolutely
necessary.
Always check the coolant level when the engine is cold.
Always refer to the chart at the left to determine the
correct cooling water to antifreeze solution mixing ratio.
Cooling System Inspection
Install a radiator filler cap tester to the radiator. Apply
testing pressure to the cooling system to check for
leakage.
The testing pressure must not exceed the specified
pressure.
Testing Pressure: 196 kPa (2 kg/cm
2/28.45 psi)
Radiator Cap Inspection
The radiator filler cap is designed to maintain coolant
pressure in the cooling system at 103 kPa (1.05
kg/cm
2/15 psi).
Check the radiator filler cap with a radiator filler cap
tester.The radiator filler cap must be replaced if it fails to hold
the specified pressure during the test procedure.
Radiator Filler Cap Pressure Valve: 88.2 – 117.6 kPa
(0.899 – 1.199 kg/cm
2/12.8 – 17.1 psi)
Negative Valve (Reference): 1.0 – 3.9 kPa
(0.01 – 0.04 kg/cm
2/0.14 – 0.57 psi)
Thermostat Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature:
83 – 87°C (181 – 189°F)
4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature:
100°C (212°F)
Valve Lift at Fully Open Position: 9.5 mm (0.374
in)0
-10
-20
-30
-40
-50
-60
10 20 30
Mixing ratio (%)
Freezing point (
C)
40 50 60
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110RS005
110RS006
031RS003

6E–5 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Conditions for Clearing the MIL/DTC 6E–159. . . . .
Diagnostic Aids 6E–159. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1562
(Flash DTC 35) System Voltage Too Low
at Cranking 6E–160. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–160. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–160. . . . . . .
Conditions for Clearing the MIL/DTC 6E–160. . . . .
Diagnostic Aids 6E–160. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1587
(Flash DTC 25) Brake SW Malfunction 6E–161. . . .
Circuit Description 6E–161. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–161. . . . . . .
Conditions for Clearing the MIL/DTC 6E–161. . . . .
Diagnostic Aids 6E–161. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1588
(Flash DTC 25) Brake SW Malfunction 6E–163. . . .
Circuit Description 6E–163. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–163. . . . . . .
Conditions for Clearing the MIL/DTC 6E–163. . . . .
Diagnostic Aids 6E–163. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0601
(Flash DTC 55) ECM Checksum Error 6E–165. . . . .
Action Taken When the DTC Sets 6E–165. . . . . . .
Conditions for Clearing the MIL/DTC 6E–165. . . . .
Diagnostic Aids 6E–165. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0650
(Flash DTC 77) Check Engine Lam Circuit
Open/Short 6E–166. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–166. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–166. . . . . . .
Conditions for Clearing the MIL/DTC 6E–166. . . . .
Diagnostic Aids 6E–166. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0654
(Flash DTC 27) Tachometer Circuit
Open/Short 6E–168. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–168. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–168. . . . . . .
Conditions for Clearing the MIL/DTC 6E–168. . . . .
Diagnostic Aids 6E–168. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1655
(Flash DTC 17) Thermo Relay Circuit
Open/Short 6E–170. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–170. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–170. . . . . . .
Conditions for Clearing the MIL/DTC 6E–170. . . . .
Diagnostic Aids 6E–170. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1657
(Flash DTC 76) ECM Main Relay Circuit
Open/Short 6E–172. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–172. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–172. . . . . . .
Conditions for Clearing the MIL/DTC 6E–172. . . . .
Diagnostic Aids 6E–172. . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Trouble Code (DTC) P1589
(Flash DTC 47) Transmission SW Circuit
Open/Short 6E–174. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–174. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–174. . . . . . .
Conditions for Clearing the MIL/DTC 6E–174. . . . .
Diagnostic Aids 6E–174. . . . . . . . . . . . . . . . . . . . . . . .
Symptom Diagnosis 6E–176. . . . . . . . . . . . . . . . . . . . .
Default Matrix Table 6E–199. . . . . . . . . . . . . . . . . . . . .
On–Vehicle Service Camshaft Position
(CMP) Sensor 6E–201. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–201. . . . . . . . . . . . . . . . . . . .
Inspection Procedure 6E–201. . . . . . . . . . . . . . . . . .
Installation Procedure 6E–201. . . . . . . . . . . . . . . . . .
Crankshaft Position (CKP) Sensor 6E–202. . . . . . . . .
Removal Procedure 6E–202. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–202. . . . . . . . . . . . . . . . . .
Engine Coolant Temperature (ECT) Sensor 6E–203.
Removal Procedure 6E–203. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–203. . . . . . . . . . . . . . . . . .
Intake Air Temperature (IAT) Sensor 6E–203. . . . . . .
Removal Procedure 6E–203. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–204. . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure (MAP) Sensor 6E–204.
Removal Procedure 6E–204. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–205. . . . . . . . . . . . . . . . . .
Oil Temperature (OT) Sensor 6E–205. . . . . . . . . . . . .
Removal Procedure 6E–205. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–206. . . . . . . . . . . . . . . . . .
Malfunction Indicator Lamp (MIL) 6E–206. . . . . . . . . .
Removal and Installation Procedure 6E–206. . . . . .
Engine Control Module (ECM) 6E–206. . . . . . . . . . . .
Service Precaution 6E–206. . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge (ESD) Damage 6E–206. . .
Removal Procedure 6E–207. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–208. . . . . . . . . . . . . . . . . .
EEPROM 6E–208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6E–208. . . . . . . . . . . . . . . . . . . .
Functional Check 6E–208. . . . . . . . . . . . . . . . . . . . . .
Intake Throttle Position (ITP) Sensor 6E–208. . . . . . .
Removal Procedure 6E–208. . . . . . . . . . . . . . . . . . . .
Function Check 6E–209. . . . . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–209. . . . . . . . . . . . . . . . . .
Vehicle Speed Sensor (VSS) 6E–210. . . . . . . . . . . . .
Removal Procedure 6E–210. . . . . . . . . . . . . . . . . . . .
Inspection Procedure 6E–210. . . . . . . . . . . . . . . . . .
Installation Procedure 6E–210. . . . . . . . . . . . . . . . . .
Air Cleaner/Air Filter 6E–211. . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–211. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–211. . . . . . . . . . . . . . . . . .
Accel Position (AP) Sensor 6E–211. . . . . . . . . . . . . . .
Removal Procedure 6E–211. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–212. . . . . . . . . . . . . . . . . .
Accelerator Pedal Replacement 6E–212. . . . . . . . . . .