1998 OPEL FRONTERA Workshop Manual

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Page 1201 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–84
ENGINE DRIVEABILITY AND EMISSIONS
Engine Cranks But Will Not Run
StepNo Ye s Va l u e ( s ) Action
301. Ignition “ON.”
2. At the CKP harness connector, connect a test light
between the ign

Page 1202 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–85 ENGINE DRIVEABILITY AND EMISSIONS
Fuel System Electrical Test
D06RW101
Circuit Description
When the ignition switch is first turned “ON,” the
powertrain control module (PCM) energizes

Page 1203 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–86
ENGINE DRIVEABILITY AND EMISSIONS
CAUTION: To reduce the risk of fire and personal
injury:
It is necessary to relieve fuel system pressure
before connecting a fuel pressure gauge

6E–86
ENGINE DRIVEABILITY AND EMISSIONS
CAUTION: To reduce the risk of fire and personal
injury:
It is necessary to relieve fuel system pressure
before connecting a fuel pressure gauge. Refer to
Fuel Pressure Relief Procedure, below.
A small amount of fuel may be released when
disconnecting the fuel lines. Cover fuel line
fittings with a shop towel before disconnecting, to
catch any fuel that may leak out. Place the towel in
an approved container when the disconnect is
completed.
Fuel Pressure Relief Procedure
1. Remove the fuel cap.
2. Remove the fuel pump relay from the underhood
relay center.
3. Start the engine and allow it to stall.
4. Crank the engine for an additional 3 seconds.
Fuel Gauge Installation
1. Remove the shoulder fitting cap.
2. Install fuel gauge 5-8840-0378-0 to the fuel feed line
located in front of and above the right side valve train
cover .
3. Reinstall the fuel pump relay.
Fuel System Electrical Test
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. Read the “Caution” above.
2. Relieve the fuel system pressure and install the fuel
pump pressure gauge to the test fitting.
3. Use Tech 2 to command the fuel pump “ON.”
Is there an immediate pressure build-up which
indicates the pump is running?
—Go to Step 3Go to Step 4
31. Verify that the pump is not running by removing the
fuel filler cap and listening.
2. Command the pump “ON” with Tech 2.
Did the pump turn “OFF” after 2 seconds?
—
Te s t
completed
Go to Step 12
41. Ignition “OFF.”
2. Remove the fuel pump relay.
3. Using a test light connected to ground, probe the
battery feed to the relay.
Did the light illuminate?
—Go to Step 6Go to Step 5
5Repair short or open battery feed to fuel pump relay.
Is the action complete?
—Verify repair—
61. Connect a test light between the two wires that
connect to the fuel pump relay pull-in coil.
2. Ignition “ON.”
Did the test light illuminate for 2 seconds and then turn
off?
—Go to Step 12Go to Step 7
71. With a test light connected to battery (–), probe the
fuel pump relay connector at the wire which runs
from the relay pull-in coil to the PCM.
2. Ignition “ON.”
Did the test light illuminate for 2 seconds and then turn
off?
—Go to Step 8Go to Step 9
8Locate and repair open in the fuel pump relay ground
circuit.
Is the action complete?
—Verify repair—

Page 1204 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–87 ENGINE DRIVEABILITY AND EMISSIONS
Fuel System Electrical Test
StepNo Ye s Va l u e ( s ) Action
9Check for short or open between the PCM and the fuel
pump relay.
Was a problem found?
—Verify

6E–87 ENGINE DRIVEABILITY AND EMISSIONS
Fuel System Electrical Test
StepNo Ye s Va l u e ( s ) Action
9Check for short or open between the PCM and the fuel
pump relay.
Was a problem found?
—Verify repairGo to Step 10
101. Check the fuel pump relay circuit for a poor terminal
connection at the PCM.
2. If a problem is found, replace terminal as necessary.
Was a problem found?
—Verify repairGo to Step 11
11Replace the PCM.
IMPORTANT:The replacement PCM must be
programmed. Refer to
UBS 98model year Immobilizer
Workshop Manual.
Is the action complete?—Verify repair—
121. Reconnect the fuel pump relay.
2. Disconnect the fuel pump electrical connector at the
fuel tank.
3. Using a test light connected to ground, probe the
fuel pump feed wire (harness side).
4. Command the fuel pump “ON” with Tech 2.
Did the light illuminate for 2 seconds?
—Go to Step 15Go to Step 13
131. Honk the horn to verify that the horn relay is
functioning.
2. Substitute the horn relay for the fuel pump relay.
3. Leave the test light connected as in step 12.
4. Command the fuel pump “ON” with Tech 2.
Did the test light illuminate for 2 seconds when the fuel
pump was commanded “ON?”
—Go to Step 17Go to Step 14
141. Re-connect the horn relay in its proper location.
2. Check for a short circuit, blown fuse or open circuit
between the relay and the fuel tank.
Is the action complete?
—Verify repair—
151. With the fuel pump electrical connector at the fuel
tank disconnected, connect a test light between the
feed wire and the ground wire (harness side).
2. Command the fuel pump “ON” with Tech 2.
Did the test light illuminate for 2 seconds?
—Go to Step 18Go to Step 16
16Repair the open circuit in the fuel pump ground wire.
Is the action complete?
—Verify repair—
171. Re-connect the horn relay in its proper location.
2. Replace the fuel pump relay.
Is the action complete?
—Verify repair—
18Replace the fuel pump.
Is the action complete?
—Verify repair—

Page 1205 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–88
ENGINE DRIVEABILITY AND EMISSIONS
Fuel System Diagnosis
140RW020
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Pump and Sender Assembly
(5) Fuel Filter
(6) Fuel Rail Rig

6E–88
ENGINE DRIVEABILITY AND EMISSIONS
Fuel System Diagnosis
140RW020
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Pump and Sender Assembly
(5) Fuel Filter
(6) Fuel Rail Right
(7) Right Bank(8) Fuel Rail Left
(9) Left Bank
(10) Fuel Pressure Control Valve
(11) Common Chamber
(12) Duty Solenoid Valve
(13) Throttle Valve
(14) Canister
(15) Evapo Shut Off Valve
Circuit Description
When the ignition switch is turned “ON,” the powertrain
control module (PCM) will turn “ON” the in-tank fuel
pump. The in-tank fuel pump will remain “ON” as long as
the engine is cranking or running and the PCM is receiving
58X crankshaft position pulses. If there are no 58X
crankshaft position pulses, the PCM will turn the in-tank
fuel pump “OFF” 2 seconds after the ignition switch is
turned “ON” or 2 seconds after the engine stops running.
The in-tank fuel pump is an electric pump within an
integral reservoir. The in-tank fuel pump supplies fuel
through an in-line fuel filter to the fuel rail assembly. The
fuel pump is designed to provide fuel at a pressure above
the pressure needed by the fuel injectors. A fuel pressure
regulator, attached to the fuel rail, keeps the fuel available
to the fuel injectors at a regulated pressure. Unused fuel
is returned to the fuel tank by a separate fuel return line.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
2. Connect the fuel pressure gauge to the fuel feed line
as shown in the fuel system illustration. Wrap a
shop towel around the fuel pressure connection in
order to absorb any fuel leakage that may occur
when installing the fuel pressure gauge. With the
ignition switch “ON” and the fuel pump running, the
fuel pressure indicated by the fuel pressure gauge
should be 333-376 kPa (48-55 psi). This pressure
is controlled by the amount of pressure the spring
inside the fuel pressure regulator can provide.
3. A fuel system that cannot maintain a constant fuel
pressure has a leak in one or more of the following
areas:
The fuel pump check valve.
The fuel pump flex line.

Page 1206 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–89 ENGINE DRIVEABILITY AND EMISSIONS
The valve or valve seat within the fuel pressure
regulator.
The fuel injector(s).
4. Fuel pressure that drops off during acceleration,
cruise, or hard

6E–89 ENGINE DRIVEABILITY AND EMISSIONS
The valve or valve seat within the fuel pressure
regulator.
The fuel injector(s).
4. Fuel pressure that drops off during acceleration,
cruise, or hard cornering may case a lean condition.
A lean condition can cause a loss of power, surging,
or misfire. A lean condition can be diagnosed using
a Tech II Tech 2. If an extremely lean condition
occurs, the oxygen sensor(s) will stop toggling. The
oxygen sensor output voltage(s) will drop below 500
mV. Also, the fuel injector pulse width will increase.
IMPORTANT:Make sure the fuel system is not
operating in the “Fuel Cut-Off Mode.”
When the engine is at idle, the manifold pressure is
low (high vacuum). This low pressure (high vacuum)
is applied to the fuel pressure regulator diaphragm.
The low pressure (high vacuum) will offset the
pressure being applied to the fuel pressure regulator
diaphragm by the spring inside the fuel pressure
regulator. When this happens, the result is lower fuel
pressure. The fuel pressure at idle will vary slightly as
the barometric pressure changes, but the fuel
pressure at idle should always be less than the fuel
pressure noted in step 2 with the engine “OFF.”
16.Check the spark plug associated with a particular
fuel injector for fouling or saturation in order to
determine if that particular fuel injector is leaking. If
checking the spark plug associated with a particular
fuel injector for fouling or saturation does not
determine that a particular fuel injector is leaking,
use the following procedure:
Remove the fuel rail, but leave the fuel lines and
injectors connected to the fuel rail. Refer to
Fuel Rail
Assembly
in On-Vehicle Service.
Lift the fuel rail just enough to leave the fuel injector
nozzles in the fuel injector ports.
CAUTION: In order to reduce the risk of fire and
personal injury that may result from fuel spraying on
the engine, verify that the fuel rail is positioned over
the fuel injector ports and verify that the fuel injector
retaining clips are intact.
Pressurize the fuel system by connecting a 10 amp
fused jumper between B+ and the fuel pump relay
connector.
Visually and physically inspect the fuel injector
nozzles for leaks.
17.A rich condition may result from the fuel pressure
being above 376 kPa (55 psi). A rich condition may
cause a DTC P0132 or a DTC P0172 to set.
Driveability conditions associated with rich
conditions can include hard starting (followed by
black smoke) and a strong sulfur smell in the
exhaust.20.This test determines if the high fuel pressure is due
to a restricted fuel return line or if the high fuel
pressure is due to a faulty fuel pressure regulator.
21.A lean condition may result from fuel pressure
below 333 kPa (48 psi). A lean condition may
cause a DTC P0131 or a DTC P0171 to set.
Driveability conditions associated with lean
conditions can include hard starting (when the
engine is cold ), hesitation, poor driveability, lack of
power, surging , and misfiring.
22.Restricting the fuel return line causes the fuel
pressure to rise above the regulated fuel pressure.
Command the fuel pump “ON” with Tech 2. The fuel
pressure should rise above 376 kPa (55 psi) as the
fuel return line becomes partially closed.
NOTE: Do not allow the fuel pressure to exceed 414 kPa
( 6 0 p s i ) . F u e l p r e s s u r e i n e x c e s s o f 4 1 4 k P a ( 6 0 p s i ) m a y
damage the fuel pressure regulator.
CAUTION: To reduce the risk of fire and personal
injury:
It is necessary to relieve fuel system pressure
before connecting a fuel pressure gauge. Refer to
Fuel Pressure Relief Procedure, below.
A small amount of fuel may be released when
disconnecting the fuel lines. Cover fuel line
fittings with a shop towel before disconnecting, to
catch any fuel that may leak out. Place the towel in
an approved container when the disconnect is
completed.
Fuel Pressure Relief Procedure
1. Remove the fuel cap.
2. Remove the fuel pump relay from the underhood
relay center.
3. Start the engine and allow it to stall.
4. Crank the engine for an additional 3 seconds.
Fuel Gauge Installation
1. Remove the shoulder fitting cap.
2. Install fuel gauge 5-8840-0378-0 to the fuel feed line
located in front of and above the right side valve train
cover.
3. Reinstall the fuel pump relay.

Page 1207 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–90
ENGINE DRIVEABILITY AND EMISSIONS
Fuel System Diagnosis
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
2

6E–90
ENGINE DRIVEABILITY AND EMISSIONS
Fuel System Diagnosis
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.”
2. Turn the air conditioning system “OFF.”
3. Relieve fuel system pressure and install the fuel
pressure gauge.
4. Turn the ignition “ON.”
NOTE: The fuel pump will run for approximately 2
seconds. Use Tech 2 to command the fuel pump “ON”.
5. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running.
Is the fuel pressure within the specified limits?
290-376 kPa
(42-55 psi)
Go to Step 3Go to Step 17
3NOTE: The fuel pressure will drop when the fuel pump
stops running, then it should stabilize and remain
constant.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant?
—Go to Step 4Go to Step 12
41. When the vehicle is at normal operation
temperature, turn the ignition “ON” to build fuel
pressure and observe the measurement on the
gauge.
2. Start the engine and observe the fuel pressure
gauge.
Did the reading drop by the amount specified after the
engine was started?
21-105 kPa
(3-15 psi)
Go to Step 5Go to Step 9
5Is fuel pressure dropping off during acceleration,
cruise, or hard cornering?
—Go to Step 6
Check for
improper fuel
6Visually and physically inspect the following items for a
restriction:
The in-pipe fuel filter.
The fuel feed line.
Was a restriction found?
—Verify repairGo to Step 7
7Remove the fuel tank and visually and physically
inspect the following items:
The fuel pump strainer for a restriction.
The fuel line for a leak.
Verify that the correct fuel pump is in the vehicle.
Was a problem found in any of these areas?
—Verify repairGo to Step 8
8Replace the fuel pump.
Is the action complete?
—Verify repair—
91. Disconnect the vacuum hose from the fuel pressure
regulator.
2. With the engine idling, apply 12-14 inches of
vacuum to the fuel pressure regulator.
Does the fuel pressure indicated by the fuel pressure
gauge drop by the amount specified?
21-105 kPa
(3-15 psi)
Go to Step 10Go to Step 11

Page 1208 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–91 ENGINE DRIVEABILITY AND EMISSIONS
Fuel System Diagnosis
StepNo Ye s Va l u e ( s ) Action
10Locate and repair the loss of vacuum to the fuel
pressure regulator.
Is the action complete

6E–91 ENGINE DRIVEABILITY AND EMISSIONS
Fuel System Diagnosis
StepNo Ye s Va l u e ( s ) Action
10Locate and repair the loss of vacuum to the fuel
pressure regulator.
Is the action complete?
—Verify repair—
11Replace the fuel pressure regulator.
Is the action complete?
—Verify repair—
121. Run the fuel pump with Tech 2.
2. After pressure has built up, turn off the pump and
clamp the supply hose shut with suitable locking
pliers.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant?
—Go to Step 13Go to Step 15
13Visually inspect the fuel supply line and repair any
leaks.
Was a problem found?
—Verify repairGo to Step 14
14Remove the fuel tank and inspect for leaky hose or
in-tank fuel line.
Was a problem found?
—Verify repairGo to Step 8
151. If the pliers are still clamped to the fuel supply hose,
remove the locking pliers.
2. With suitable locking pliers, clamp the fuel return
line to prevent fuel from returning to the fuel tank.
3. Run the fuel pump with Tech 2.
4. After pressure has built up, remove power to the
pump.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant?
—Go to Step 11Go to Step 16
16Locate and replace any leaking fuel injector(s).
Is the action complete?
—Verify repair—
17Is the fuel pressure indicated by the fuel pressure
gauge above the specified limit?376 kPa
(55 psi)
Go to Step 18Go to Step 21
181. Relieve the fuel pressure. Refer to the Fuel
Pressure Relief.
2. Disconnect the fuel return line from the fuel rail.
3. Attach a length of flexible hose to the fuel rail return
outlet passage.
4. Place the open end of the flexible hose into an
approved gasoline container.
5. Run the fuel pump with Tech 2.
6. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running.
Is the fuel pressure within the specified limits?
290-376 kPa
(42-55 psi)
Go to Step 19Go to Step 20
19Locate and correct the restriction in the fuel return line.
Is the action complete?
—Verify repair—
20Visually and physically inspect the fuel rail outlet
passages for a restriction.
Was a restriction found?
—Verify repairGo to Step 11
21Is the fuel pressure indicated by the fuel pressure
gauge above the specified value?
0kPa (0psi)Go to Step 22Go to Step 23

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