1998 OPEL FRONTERA clutch

6E–262
ENGINE DRIVEABILITY AND EMISSIONS
Symptom Diagnosis
Preliminary Checks
Before using this section, perform the “On-Board
Diagnostic (OBD) System Check” and verify all of the
following items:
The powertrain control module (PCM) and malfunction
indicator lamp (MIL) (Service Engine Soon lamp) are
operating correctly.
There are no DTC(s) stored.
Tech 2 data is within normal operating range. Refer to
Typical Scan Data Values.
Verify the customer complaint and locate the correct
symptom in the table of contents. Perform the
procedure included in the symptom chart.
Visual/Physical Check
Several of the symptom procedures call for a careful
visual/physical check. This can lead to correcting a
problem without further checks and can save valuable
time.
This check should include the following items:
PCM grounds for cleanliness, tightness and proper
location.
Vacuum hoses for splits, kinks, and proper
connections, as shown on the “Vehicle Emission
Control Information” label. Check thoroughly for any
type of leak or restriction.
Air intake ducts for collapsed or damaged areas.
Air leaks at throttle body mounting area, mass air flow
(MAF) sensor and intake manifold sealing surfaces.
Ignition wires for cracking, hardness, and carbon
tracking.
Wiring for proper connections, pinches and cuts.
Intermittents
IMPORTANT:An intermittent problem may or may not
turn on the malfunction indicator lamp (MIL) or store a
DTC. DO NOT use the Diagnostic Trouble Code (DTC)
charts for intermittent problems. The fault must be
present to locate the problem.
Most intermittent problems are caused by faulty electrical
connections or wiring. Perform a careful visual/physical
check for the following conditions:
Poor mating of the connector halves or a terminal not
fully seated in the connector (backed out).
Improperly formed or damaged terminal.
All connector terminals in the problem circuit should be
carefully checked for proper contact tension.
Poor terminal-to-wire connection. This requires
removing the terminal from the connector body to
check.
Road test the vehicle with a J 39200 Digital Multimeter
connected to a suspected circuit. An abnormal voltage
when the malfunction occurs is a good indication that
there is a fault in the circuit being monitored.
Use Tech 2 to help detect intermittent conditions. Tech 2s
have several features that can be used to locate anintermittent condition. Use the following feature to find
intermittent faults:
Using Tech 2’s “Freeze Frame” buffer or “Failure
Records” buffer can aid in locating an intermittent
condition. Review and record the information in the
freeze frame or failure record associated with the
intermittent DTC being diagnosed. The vehicle can be
driven within the conditions that were present when the
DTC originally set.
To check for loss of diagnostic code memory, disconnect
the MAP sensor and idle the engine until the MIL (Service
Engine Soon lamp) comes on. DTC P0107 should be
stored and kept in memory when the ignition is turned
“OFF.” If not, the PCM is faulty. When this test is
completed, make sure that you clear the DTC P0107 from
memory.
An intermittent MIL (Service Engine Soon lamp) with no
stored DTC may be caused by the following:
Ignition coil shorted to ground and arcing at ignition
wires or plugs.
MIL (Service Engine Soon lamp) wire to PCM shorted
to ground.
Poor PCM grounds. Refer to the PCM wiring
diagrams.
Check for improper installation of electrical options such
as lights, cellular phones, etc. Route ignition coil wiring
away from the ignition coils. Check all wires from the
PCM to the ignition coil for poor connections.
Check for an open diode across the A/C compressor
clutch and check for other open diodes (refer to wiring
diagrams in
Electrical Diagnosis).
If problem has not been found, refer to
PCM Connector
Symptom
tables.

6E–265 ENGINE DRIVEABILITY AND EMISSIONS
Surges and/or Chuggles Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Engine power variation under steady throttle or cruise.
Feels like the vehicle speeds up and slows down with
no change in the accelerator pedal.
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/Physic
al Check
4Be sure that the driver understands transmission
torque converter clutch and A/C compressor operation
as explained in the owner’s manual.
Inform the customer how the TCC and the A/C clutch
operate.
Is the customer experiencing a normal condition?
—System OKGo to Step 5
51. Check the the fuel control heated oxygen sensors
(HO2S, B1S1 and B2S1). The fuel control heated
oxygen sensors (HO2S) should respond quickly to
different throttle positions. If they don’t, check them
for silicon or other contaminants from fuel or use of
improper RTV sealant. The sensors may have a
white powdery coating.
Silicon contamination causes a high but false
HO2S signal voltage (rich exhaust indication).
The PCM will then reduce the amount of fuel
delivered to the engine, causing a severe
driveability problem. For more information, refer
to
Powertrain Control Module (PCM) and Sensors.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 6
61. Check the fuel pressure. Refer to Fuel System
Pressure Test
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
7Monitor the long term fuel trim on Tech 2.
Is the long term fuel trim significantly in the negative
range (rich condition)?
—Go to Step 8Go to Step 9
81. Check items that can cause the engine to run rich.
Refer to
Diagnostic Aids in DTC P0172 Diagnostic
Support
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Go to Step 10Verify repair
91. Check items that can cause the engine to run lean.
Refer to
Diagnostic Aids in DTC P0171.
2. If a problem is found, repair as necessary.
Was a problem found?
—Go to Step 10Verify repair

6E–269 ENGINE DRIVEABILITY AND EMISSIONS
Lack of Power, Sluggish or Spongy Symptom
StepNo Ye s Va l u e ( s ) Action
111. Check the PCM grounds for the cleanliness,
tightness and proper locations. Refer to the PCM
wiring diagrams in
Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 12
121. 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 three-way
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 13
131. Check the torque converter clutch (TCC) for proper
operation. Refer to
4L30-E Transmission
Diagnosis
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 14
141. Check for an engine mechanical problem. Check
for low compression, incorrect or worn camshaft,
loose timing belt, etc. Refer to
Engine Mechanical.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 15
151. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Te c h 2 d a t a
Freeze Frame data/Failure Records buffer
All electrical connections within a suspected
circuit and/or system.
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repair
Contact
Te c h n i c a l
Assistance

6E–289 ENGINE DRIVEABILITY AND EMISSIONS
Symptoms Default Section(s)Initial Diagnosis
Lack of Power, Sluggish or Spongy1. OBD system check.
2. Fuel system diagnosis.
3. Ignition system.
4. Knock sensor.
5. EGR operation.
6. EGR system check.Refer to Exhaust System in
Engine Exhaust, TCC Operation,
Calibration ID/Service Bulletins
Detonation/Spark Knock1. OBD system check.
2. Transmission range switch.
3. EGR operation.
4. EGR system check.
5. TCC operation.
6. Fuel system diagnosis.
7. Ignition system.
8. Knock sensor.TCC operation, Cooling System,
Ignition System Check,
Calibration ID/Service Bulletins
Hesitation, Sag, Stumble1. OBD system check.
2. TP.
3. MAP output check.
4. Fuel system diagnosis.
5. Fuel injector and fuel injector
balance test.
6. Ignition system.EGR Operation, EGR System
Check, Generator Output
Voltage (refer to
Chassis
Electrical
), Calibration ID/Service
Bulletins, Ignition System Check
Cuts Out, Misses1. OBD system check.
2. Cylinder balance test.Ignition System Check
Rough, Unstable, or Incorrect Idle,
Stalling1. OBD system check.
2. Fuel injector and fuel injector
balance test.
3. Ignition system.
4. IAC operation.
5. EGR operation.MAP Output Check, Throttle
Linkage, IAC System Check,
EGR System Check, A/C Clutch
Control Circuit Diagnosis,
Crankcase Ventilation System,
Calibration ID/Service Bulletins,
Generator Output Voltage (refer
to
Chassis Electrical), Exhaust
Diagnosis
Poor Fuel Economy1. OBD system check.
2. Careful visual/physical inspection.
3. Ignition system.
4. Cooling system.TCC Operation, Exhaust System
(refer to
Engine Exhaust)
Engine Cranks But Will Not Run1. OBD system check.Fuel System Electrical
Diagnosis, Fuel System
Diagnosis, Fuel Injector and Fuel
Injector Balance Test.
Excessive Exhaust Emissions or
Odors1. OBD system check.
2. Emission test.
3. Cooling system.
4. Fuel system diagnosis.
5. Fuel injector and fuel injector
balance test.
6. Crankcase ventilation system.
7. Ignition system.
8. MAP output check.EGR System Check, Exhaust
Diagnosis, Calibration ID/Service
Bulletins
Dieseling, Run-On1. OBD system check.
2. Careful visual/physical inspection.
3. Fuel system diagnosis.—

6E–335 ENGINE DRIVEABILITY AND EMISSIONS
General Description
General Description (PCM and
Sensors)
58X Reference PCM Input
The powertrain control module (PCM) uses this signal
from the crankshaft position (CKP) sensor to calculate
engine RPM and crankshaft position at all engine speeds.
The PCM also uses the pulses on this circuit to initiate
injector pulses. If the PCM receives no pulses on this
circuit, DTC P0337 will set. The engine will not start and
run without using the 58X reference signal.
A/C Request Signal
This signal tells the PCM when the A/C mode is selected
at the A/C control head. The PCM uses this to adjust the
idle speed before turning “ON” the A/C clutch. The A/C
compressor will be inoperative if this signal is not
available to the PCM.
Refer to
A/C Clutch Circuit Diagnosis for A/C wiring
diagrams and diagnosis for the A/C electrical system.
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor provides a signal
used by the powertrain control module (PCM) to calculate
the ignition sequence. The CKP sensor initiates the 58X
reference pulses which the PCM uses to calculate RPM
and crankshaft position.
Refer to
Electronic Ignition System for additional
information.
0013
Camshaft Position (CMP) Sensor and
Signal
The camshaft position (CMP) sensor sends a CMP signal
t o t h e P C M . T h e P C M u s e s t h i s s i g n a l a s a “ s y n c p u l s e ” t otrigger the injectors in the proper sequence. The PCM
uses the CMP signal to indicate the position of the #1
piston during its power stroke. This allows the PCM to
calculate true sequential fuel injection (SFI) mode of
operation. If the PCM detects an incorrect CMP signal
while the engine is running, DTC P0341 will set. If the
CMP signal is lost while the engine is running, the fuel
injection system will shift to a calculated sequential fuel
injection mode based on the last fuel injection pulse, and
the engine will continue to run. As long as the fault is
present, the engine can be restarted. It will run in the
calculated sequential mode with a 1-in-6 chance of the
injector sequence being correct.
Refer to
DTC P0341 for further information.
0014
Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature (ECT) sensor is a
thermistor (a resistor which changes value based on
temperature) mounted in the engine coolant stream. Low
coolant temperature produces a high resistance of
100,000 ohms at –40
C (–40F). High temperature
causes a low resistance of 70 ohms at 130
C (266F).
The PCM supplies a 5-volt signal to the ECT sensor
through resistors in the PCM and measures the voltage.
The signal voltage will be high when the engine is cold and
low when the engine is hot. By measuring the voltage, the
PCM calculates the engine coolant temperature. Engine
coolant temperature affects most of the systems that the
PCM controls.
Tech 2 displays engine coolant temperature in degrees.
After engine start-up, the temperature should rise steadily
to about 85
C (185F). It then stabilizes when the
thermostat opens. If the engine has not been run for
several hours (overnight), the engine coolant
temperature and intake air temperature displays should
be close to each other. A hard fault in the engine coolant
sensor circuit will set DTC P0177 or DTC P0118. An
intermittent fault will set a DTC P1114 or P1115.

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–349 ENGINE DRIVEABILITY AND EMISSIONS
Damage during re-gapping can happen if the gapping
tool is pushed against the center electrode or the
insulator around it, causing the insulator to crack.
When re-gapping a spark plug, make the adjustment
by bending only the ground side terminal, keeping the
tool clear of other parts.
”Heat shock” breakage in the lower insulator tip
generally occurs during several engine operating
conditions (high speeds or heavy loading) and may be
caused by over-advanced timing or low grade fuels.
Heat shock refers to a rapid increase in the tip
temperature that causes the insulator material to
crack.
Spark plugs with less than the recommended amount of
service can sometimes be cleaned and re-gapped , then
returned to service. However, if there is any doubt about
the serviceability of a spark plug, replace it. Spark plugs
with cracked or broken insulators should always be
replaced.
A/C Clutch Diagnosis
A/C Clutch Circuit Operation
A 12-volt signal is supplied to the A/C request input of the
PCM when the A/C is selected through the A/C control
switch.
The A/C compressor clutch relay is controlled through the
PCM. This allows the PCM to modify the idle air control
position prior to the A/C clutch engagement for better idle
quality. If the engine operating conditions are within their
specified calibrated acceptable ranges, the PCM will
enable the A/C compressor relay. This is done by
providing a ground path for the A/C relay coil within the
PCM. When the A/C compressor relay is enabled,
battery voltage is supplied to the compressor clutch coil.
The PCM will enable the A/C compressor clutch
whenever the engine is running and the A/C has been
requested. The PCM will not enable the A/C compressor
clutch if any of the following conditions are met:
The throttle is greater than 90%.
The engine speed is greater than 6315 RPM.
The ECT is greater than 119C (246F).
The IAT is less than 5C (41F).
The throttle is more than 80% open.
A/C Clutch Circuit Purpose
The A/C compressor operation is controlled by the
powertrain control module (PCM) for the following
reasons:
It improvises idle quality during compressor clutch
engagement.
It improvises wide open throttle (WOT) performance.
It provides A/C compressor protection from operation
with incorrect refrigerant pressures.
The A/C electrical system consists of the following
components:
The A/C control head.
The A/C refrigerant pressure switches.
The A/C compressor clutch.
The A/C compressor clutch relay.
The PCM.
A/C Request Signal
This signal tells the PCM when the A/C mode is selected
at the A/C control head. The PCM uses this to adjust the
idle speed before turning on the A/C clutch. The A/C
compressor will be inoperative if this signal is not
available to the PCM.
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.
057RW002
Linear EGR Valve
The main element of the system is the linear EGR valve.
The EGR valve feeds small amounts of exhaust gas back
into the combustion chamber. The fuel/air mixture will be
diluted and combustion temperatures reduced.
Linear EGR Control
The PCM monitors the EGR actual positron and adjusts
the pintle position accordingly. The uses information from
the following sensors to control the pintle position:
Engine coolant temperature (ECT) sensor.
Throttle position (TP) sensor.
Mass air flow (MAF) sensor.
Linear EGR Valve Operation and Results
of Incorrect Operation
The linear EGR valve is designed to accurately supply
EGR to the engine independent of intake manifold
vacuum. The valve controls EGR flow from the exhaust

6A – 28 ENGINE MECHANICAL
ENGINE ASSEMBLY
For General Export
For Europe
F06R200004
REMOVAL
1. Remove battery.
2. Drain engine coolant
3. Disconnect window washer hose and remove
engine hood.
4. Radiator Hose
1) Disconnect upper and lower hoses from engine
side.
5. Fan Shroud
1) Disengage clips and remove upper and lower
fan shrouds.
6. Cooling Fan Assembly
1) Remove cooling fan assembly fixing nuts,
cooling fan assembly.
7. Radiator Assembly1) Remove bracket and radiator assembly.
8. Air Cleaner Cover & Air Duct
9. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
10. Engine Ground Cable
1) Disconnect ground cable from A/C compressor
bracket.
11. AC Generator Harness
1) Disconnect B terminal and harness connector
from AC generator.
12. A/C Compressor Assembly
1) Disconnect magnetic clutch harness connector.
2) Remove A/C compressor fixing bolt (rear under
side of compressor).
3) Remove fixing bolts (upper and front lower side
of compressor) and set A/C compressor
assembly with pipe lines on battery carrier.