1998 OPEL FRONTERA oil pump

ENGINE FUEL 6C – 19
HIGH PRESSURE OIL PIPE INSTALLATION
1. Install upper bracket to two way valve, tighten them
temporarily.
2. Install pipe A to two way valve, tighten pipe A
temporarily with union nut D.
3. Install two way valve assembly to cylinder block,
tighgten with union nut C temporarily.
4. Install pipe B to two way valve, tighten union nut E
and union nut F temporarily.
5. Tighten upper bracket to specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
6. Tighten union nut in the following order, union nut
C, D, F, and E to the specified torque.
Torque : 80 Nꞏm (8.1 kgꞏm/57.9 lb ft)
7. Tighten lower bracket to the specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
NOTE: Wash inside pipe, inside union nut and O-ring
seal surface to remove engine oil and foreign materials.
6
5
7
9
8
114
1
2
3 10
Legend
(1) Union Nut F
(2) Pipe B
(3) Union Nut E
(4) Upper Bracket
(5) Two Way Valve
(6) Union Nut D(7) Pipe A
(8) Union Nut C
(9) Lower Bracket
(10) To Oil Rail
(11) To High Pressure Oil Pump
052R200001

6E–19 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Component Locator
Engine Component Locator Table
F06RW051
NumberNameLocation
1AP (Accelerator Pedal Position) SensorAP Bracket
2CKP (Crankshaft Position) SensorInside the right front flywheel Housing
3Oil RailMounted on the camshaft carrier
4Oil (Rail) Pressure SensorMounted on the Oil Rail
5OT (Oil Temperature) SensorMounted on the Oil Rail
6Fuel InjectorIn the Cylinder Head Cover
7Fuel Return OrificeInside the Cylinder Head
8FT (Fuel Temperature) SensorFuel Return Adaptor
9IntercoolerOn the Cylinder Head Cover
10Intake Throttle MotorBehind the Intake Manifold
11Intake ThrottleBehind the Intake Manifold
122 Way Check ValveBelow the Intake Manifold
13VSV (Vacuum Switching Valve)At the left Cylinder Body
14EGR Pressure SensorBelow the Intake Manifold
15Fuel FilterAt the left Engine Room
16CMP (Camshaft Position) SensorOn the forward of Timing Gear Case
17IAT (Intake Air Temperature) SensorBelow the Intake Manifold
18ECT (Engine Coolant Temperature)Thermostat Housing
19High Pressure Oil PumpOn the back Timing Gear Case

6E–20
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
NumberNameLocation
20Rail Pressure Control ValveIn the High Pressure Oil Pump
21Fuel PumpIn the High Pressure Oil Pump
22EVRVOn the Intake Manifold
23MAP (Manifold Absolute Pressure) SensorOn the Intake Manifold
24EGR ValveOn the Intake Manifold
25Air CleanerAt the left Engine Room
26ECMBehind the Air Cleaner

6E–34
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Fuel Injection System
060RW178
Legend
(1) ECM
(2) Meter Panel
(3) Battery
(4) Oil Temp Sensor
(5) Rail Pressure Sensor
(6) Glow Relay
(7) Oil Rail
(8) Tech–2
(9) A/C Comp Relay
(10) RPCV
(11) Intake Air Temp Sensor
(12) Engine Coolant Temp Sensor
(13) MAP Sensor
(14) EGR Valve
(15) EGR Pressure Sensor(16) High Pressure Oil Pump
(17) Fuel Pump
(18) VSV
(19) EXH Throttle VSV1
(20) EXH Throttle VSV2
(21) EVRV
(22) Engine Harness Connector
(23) QWS Relay
(24) APS
(25) T.O.D
(26) ECT
(27) OBD
(28) TDC
(29) Injector
(30) Edge Filter

6E–35 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Guid to the System
Fuel Injection system is an HEUI (Hydraulically
Actuated, Electronically Controlled, Unit, Injector)
type. In this type of injector system, the oil
pressurized by means of High Pressure Oil Pump
(16) is fed through Rail Pressure Control Valve (10)
and Oil Rail (7) to Injector (29) from which fuel is
injected under this oil pressure.
For diagnosis, therefore, the Rail Pressure as well as
the Electric Circuit must be inspected.
On-Board Diagnostic (OBD) System Check
A Group
060RW135

6E–53 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
System Check
StepActionVa l u e ( s )Ye sNo
1Move the valve up and down to check the slide
resistance.
Is the slide resistance large?
—Go to Step 8Go to Step 2
21. Set the transmission at “Park” or “Neutral”.
2. Put the engine in warming-up operation by idling.
(The engine temperature should be 80
C or more)
3. Disconnect the vacuum hose from the EGR valve.
4. Apply a vacuum of 250 mmHg to the EGR valve by
the vacuum pump (mighty pack).
Does the vibration due to engine operation become
larger?
—Go to Step 3Go to Step 9
31. Check if there is not any damage on the vacuum
hose from the vacuum pump to the EGR valve.
2. Install the vacuum pump (mighty pack) to the EGR
valve.
Does the vacuum became 250 mmHg or more at that
time?
250 mmHg or
more
Go to Step 4Go to Step 8
4Install the EGR valve and the vacuum hose formally
and increase the engine revolution speed to 3000 rpm.
Can both EGR valve 1 and EGR valve 2 be opened and
closed?
—
The system is
normal
Go to Step 5
5Measure the resistance of the VSV: EGR coil.
Is the resistance value in the range of 30
to 50 ?30 50 Go to Step 6Go to Step 10
6Measure the resistance of the EVRV: EGR coil.
Is the resistance value in the range of 10
to 13 ?10 13 Go to Step 7Go to Step 11
7Was the harness open or poor connection?—Go to Step 12Go to Step 13
8Replace the EGR valve ASM.
Is the action complete?
—Verify repair—
9Clean or replace the EGR valve ASM.
Is the action complete?
—Verify repair—
10Replace the EGR VSV.
Is the action complete?
—Verify repair—
11Replace the EGR EVSV.
Is the action complete?
—Verify repair—
12Repair the harness.
Is the action complete?
—Verify repair—
13Replace the ECM (Refer to the Data Programming in
Case of ECM change).
Is the action complete?
—Verify repair—

6E–87 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
DTC P1193 – RPCV 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
21. Ignition “ON,” engine “ON.”
2. Observe the “Rail Oil Pressure” display on the Tech
2.
Is the “Rail Oil Pressure” below the specified value?
3.5 5 MpaGo to Step 4Go to Step 3
3Replace the RPCV.
Is the action complete?
—Go to Step 2—
41. Engine “On”.
2. Using the Tech 2, operate “RPCV”.
3. Check the combustion noise.
Was the combustion noise change?
——Go to Step 5
5Check the RPCV circuit. (Fuse 15A to J1-14)
Was the RPCV circuit damaged?
—Go to Step 6Go to Step 7
6Repair the RPCV circuit.
Is the action complete?
—Verify repair—
7Replace the ECM (Refer to the Data Programming in
Case of ECM change).
Is the action complete?
—Verify repairGo to Step 8
8Replace the high pressure oil pump.
Is the action complete?
—Verify repair—

6E–92
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1196 (Flash DTC 62)
Rail Pressure System High Warning
060RW178
Legend
(1) ECM
(2) Meter Panel
(3) Battery
(4) Oil Temp Sensor
(5) Rail Pressure Sensor
(6) Glow Relay
(7) Oil Rail
(8) Tech–2
(9) A/C Comp Relay
(10) RPCV
(11) Intake Air Temp Sensor
(12) Engine Coolant Temp Sensor
(13) MAP Sensor
(14) EGR Valve
(15) EGR Pressure Sensor(16) High Pressure Oil Pump
(17) Fuel Pump
(18) VSV
(19) EXH Throttle VSV1
(20) EXH Throttle VSV2
(21) EVRV
(22) Engine Harness Connector
(23) QWS Relay
(24) AP Sensor
(25) T.O.D
(26) ECT
(27) OBD
(28) TDC
(29) Injector
(30) Edge Filter