1998 OPEL FRONTERA stop start

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–26
Checking Failed TOD Control Unit Pin
NOTE:
1. Unplug the ECU connector and the pins, unless
otherwise specified.2. Before removing the ECU, turn off the ignition switch.
3. If the standard values are not observed, check the
pins with other testers.
Check
Pin
No.Circuit to be
testedIgnition
Switch
PositionEngine
StateMultimeter
Scale/
RangeMeasure
between Pin
NumberStandard ValveNote
14D-G MAPOFFSTOP14, 19Continuity : OK
(Gasoline)
20P-GNDOFFSTOP20, 19Continuity : OK
19GNDOFFSTOP19, GNDContinuity : OK
84H SWOFFSTOP8, 19No continuity (high,
4L) and continuity
(N) : OK
94L SWOFFSTOP9, 19No continuity (high)
and continuity (4L,
N) : OK
10AXLE SWONRUN10, 19Continuity : OKRemove ECU and start the engine. Move
the vehicle forth and back to connect axle
surely.
13DIAGOFFSTOP13 (TOD), 8
(DLC Con-
nector)Continuity : OKDLC connector terminal 8
25IND.aONSTOPDCV25 (+), 19 (–)8.0 14.5 VLighting SW ON : 0V
Lighting SW OFF : 8.0 14.5 V
26IND.bONSTOPDCV26 (+), 19 (–)8.0 14.5 V
27IND.cONSTOPDCV27 (+), 19 (–)8.0 14.5 V
30CHECK
LAMPONSTOPDCV30 (+), 19 (–)8.0 14.5 V
11ABS INONSTOPDCV11 (+), 19 (–)11 . 5 14.5 V
15Ref.ONSTOPDCV15 (+), 19 (–)5 9 VConnect ECU
24Ft.(+)ONSTOPDCV24 (+), 19 (–)0.7 6 VConnect ECU (off one tooth of speed
sensor ring) and move the vehicle making
sure of voltage change.
23Rr.(+)ONSTOPDCV23 (+), 19 (–)0.7 6 VConnect ECU (off one tooth of speed
sensor ring) and move the vehicle making
sure of voltage change.
18COM(-)ONSTOPDCV18 (+), 19 (–)0VConnect ECU
1VigONSTOPDCV1 (+), 19 (–)8 14.5 V
7BRAKEOFFSTOPDCV7 (+), 19 (–)8 14.5 VPress brake pedal
21TPSONSTOPDCV21 (+), 19 (–)0.2 4.6 VStep on the accelerator pedal and make
sure that voltage changes.
34WD OUTOFFSTOP3, 197 12 kDisconnect battery GND terminal
5ADC(+)OFFSTOP5, 1910 30 Disconnect battery GND terminal
4SOL(+)OFFSTOP4, 191.0 5.0 Disconnect battery GND terminal
12TOD SWONSTOPDCV12 (+), 19 (–)SW OFF : 0 V
SW ON : 8.0 14.5 VSW OFF : Contact point open
SW ON : Contact point close
6LIGHTINGONSTOPDCV6 (+), 19 (–)SW OFF : 8.0 14.5
V
SW ON : 0 V
28AUTO INDIONSTOPDCV28 (+), 19 (–)TOD : 0 V
2H & 4L : 8.0 14.5
VLighting SW ON : 0V
Lighting SW OFF : 8.0 14.5 V
29RR INDIONSTOPDCV29 (+), 19 (–)0 V
17US/JAPOFFSTOP17 (+), 19 (–)No continuity : OK

4D2–13 TRANSFER CASE (TOD)
2. Strike the speed gear and tone wheel with a rod or
other appropriate tool from the outside of the transfer
cover assembly, and remove the ball bearing and
speed gear and tone wheel.
NOTE: Be careful not to damage the speed gear teeth.
266RW018
3. Remove the stopper plate on the back with a
precision screwdriver or other appropriate tool
starting from the small lock of the plate.
NOTE: Be careful not to damage the stopper plate during
the work.
261RW042
4. Using a terminal pull-out tool or an equivalent tool,
push down the lock to unlatch the terminal for the coil
assembly, and pull the terminal out.
NOTE: Be careful not to damage other terminals.
261RW032
5. Remove the fixing nuts of the coil assembly from the
outside of the transfer cover assembly. Remove the
coil assembly from the transfer cover.
261RW030

5A–5 BRAKE CONTROL SYSTEM
FR
Front Right
GEN
Generator
MV
Millivolts
RL
Rear Left
RR
Rear RightRPS
Revolution per Second
VDC
Vo l t s D C
VA C
Vo l t s A C
W/L
Warning Light
WSS
Wheel Speed Sensor
General Diagnosis
General Information
ABS malfunction can be classified into two types, those
which can be detected by the ABS warning light and those
which can be detected as a vehicle abnormality by the
driver.
In either case, locate the fault in accordance with the
“BASIC DIAGNOSTIC FLOWCHART” and repair.
Please refer to Section 5C for the diagnosis of
mechanical troubles such as brake noise, brake judder
(brake pedal or vehicle vibration felt when braking),
uneven braking, and parking brake trouble.
ABS Service Precautions
Required Tools and Items:
Box Wrench
Brake Fluid
Special Tool
Some diagnosis procedures in this section require the
installation of a special tool.
J-39200 High Impedance Multimeter
When circuit measurements are requested, use a circuit
tester with high impedance.
Computer System Service Precautions
The Anti-lock Brake System interfaces directly with the
Electronic Hydraulic Control Unit (EHCU) which is a
control computer that is similar in some regards to the
Powertrain Control Module. These modules are designed
to withstand normal current draws associated with
vehicle operation. However, care must be taken to avoid
overloading any of the EHCU circuits. In testing for opens
or shorts, do not ground or apply voltage to any of the
circuits unless instructed to do so by the appropriate
diagnostic procedure. These circuits should only be
tested with a high impedance multimeter (J-39200) or
special tools as described in this section. Power should
never be removed or applied to any control module with
the ignition in the “ON” position.
Before removing or connecting battery cables, fuses or
connectors, always turn the ignition switch to the “OFF”
position.
General Service Precautions
The following are general precautions which should be
observed when servicing and diagnosing the Anti-lock
Brake System and/or other vehicle systems. Failure toobserve these precautions may result in Anti-lock Brake
System damage.
If welding work is to be performed on the vehicle using
an electric arc welder, the EHCU and valve block
connectors should be disconnected before the
welding operation begins.
The EHCU and valve block connectors should never
be connected or disconnected with the ignition “ON” .
EHCU of the Anti-lock Brake System are not
separately serviceable and must be replaced as
assemblies. Do not disassemble any component
which is designated as non-serviceable in this
Section.
If only rear wheels are rotated using jacks or drum
tester, the system will diagnose a speed sensor
malfunction and the “ABS” warning light will
illuminate. But actually no trouble exists. After
inspection stop the engine once and re-start it, then
make sure that the “ABS” warning light does not
illuminate.
If the battery has been discharged
The engine may stall if the battery has been completely
discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS)
requires a large quantity of electricity. In this case, wait
until the battery is recharged, or set the ABS to a
non-operative state by removing the fuse for the ABS
(40A). After the battery has been recharged, stop the
engine and install the ABS fuse. Start the engine again,
and confirm that the ABS warning light does not light.
Note on Intermittents
As with virtually any electronic system, it is difficult to
identify an intermittent failure. In such a case duplicating
the system malfunction during a test drive or a good
description of vehicle behavior from the customer may be
helpful in locating a “most likely” failed component or
circuit. The symptom diagnosis chart may also be useful
in isolating the failure. Most intermittent problems are
caused by faulty electrical connections or wiring. When
an intermittent failure is encountered, check suspect
circuits for:
Suspected harness damage.
Poor mating of connector halves or terminals not fully
seated in the connector body (backed out).
Improperly formed or damaged terminals.

5A–6
BRAKE CONTROL SYSTEM
Test Driving ABS Complaint Vehicles
In case that there has been an malfunction in the lighting
pattern of “ABS” warning light, the fault can be located in
accordance with the “DIAGNOSIS BY “ABS” WARNING
LIGHT ILLUMINATION PATTERN” . In case of such
trouble as can be detected by the driver as a vehicle
symptom, however, it is necessary to give a test drive
following the test procedure mentioned below, thereby
reproducing the symptom for trouble diagnosis on a
symptom basis:
1. Start the engine and make sure that the “ABS” W/L
goes OFF. If the W/L remains ON, it means that the
Diagnostic Trouble Code (DTC) is stored. Therefore,
read the code and locate the fault.
2. Start the vehicle and accelerate to about 30 km/h (19
mph) or more.
3. Slowly brake and stop the vehicle completely.
4. Then restart the vehicle and accelerate to about 40
km/h (25 mph) or more.
5. Brake at a time so as to actuate the ABS and stop the
vehicle.
6. Be cautious of abnormality during the test. If the W/L
is actuated while driving, read the DTC and locate the
fault.
7. If the abnormality is not reproduced by the test, make
best efforts to reproduce the situation reported by the
customer.
8. If the abnormality has been detected, repair in
accordance with the “SYMPTOM DIAGNOSIS” .NOTE:Be sure to give a test drive on a wide, even road with
little traffic.
If an abnormality is detected, be sure to suspend the
test and start trouble diagnosis at once.
“ABS” Warning Light
When ABS trouble occurs and actuates when possible
the “ABS” warning light, the trouble code corresponding
to the trouble is stored in the EHCU. Only the ordinary
brake system is available when the ABS is turned off.
When the “ABS” warning light is actuated, if the starter
switch is set ON after setting it OFF once, the EHCU
checks up on the entire system and, if there is no
abnormality, judges ABS to work currently and the
warning light works normally even though the trouble
code is stored.
NOTE: Illumination of the “ABS” warning light indicates
that anti-lock braking is no longer available. Power
assisted braking without anti-lock control is still available.
Normal Operation
“ABS” Warning Light
W h e n t h e i g n i t i o n i s f i r s t m o v e d f r o m “ O F F ” t o “ R U N ” , t h e
amber “ABS” warning light will turn “ON” . The “ABS”
warning light will turn “ON” during engine starting and will
usually stay “ON” for approximately three seconds after
the ignition switch is returned to the “ON” position. The
warning light should remain “OFF” at all other times.
Basic Diagnostic Flow Chart
StepActionYe sNo
11. Customer complaint.
2. Questioning to customer.
3. Basic inspection (Refer to “Basic inspection procedure”)
Using TECH 2?
Go to Step 2Go to Step 4
2Make sure of DTC by mode “F0: Diagnostic Trouble Codes”.
Is EHCU including DTC?
Go to Step 3Go to Step 5
31. Repair of faulty part.
2. Elimination of DTC.
3. Inspection of “ABS” W/L Illumination pattern with ignition SW
“ON”.
4. Test drive.
Does repeat trouble?
Repeat the
diagnosis it the
symptom or DTC
appears again Go
to Step 1
Go to Step 5
4Check if the DTC is stored.
Is EHCU including DTC?
Go to Step 3
Trouble diagnosis
based on
symptom (Refer
to “SYMPTOM
DIAGNOSIS”) Go
to Step 3
51. Reconnect all components and ensure all component are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
FinishedGo to Step 5

5A–11 BRAKE CONTROL SYSTEM
Data List
DisplayContentOK/NG Criteria for Data
Battery VoltageVo l t a g eBetween 10-16.9V
Brake Light SwitchOpen/CloseOpen(0V) when pedal is released
Closed(12V) when pedal is depressed.
Front Left Wheel Speed
Front Right Wheel Speed
Rear Left Wheel Speed
Rear Right Wheel SpeedMPH(km/h)Start the vehicle and make sure of linear change in each
wheel speed.
Turn each wheel by hand and make sure that each
speed data change.
Wheel Sensor StatusOK/NGTo be OK usually
G-sensorLow/HighTo be Low usually
Transfer Monitor(TOD)2 Wheel Drive
4 Wheel DriveWhen 2WD: 2 Wheel Drive
When 4WD: 4 Wheel Drive
Off-Road Switch
(Transmission Input)
Active/InactiveWhen shift lever position is 1, 2 and R: Active (M/T)
(Transmission Input)When shift lever position is L and R: Active (A/T)
Valve RelayActive/InactiveTo be Active usually
ABS StateON/OFFTo be OFF usually
ABS RelayActive/InactiveTo be Active usually
Return Pump RelayActive/InactiveTo be Inactive usually
Front Left Isolation ValveActive/InactiveTo be Inactive usually
Front Left Dump Valve
Front Right Isolation Valve
Front Right Dump Valve
Rear Isolation Valve
Rear Dump Valve
ABS Warning LampON/OFFTo be ON usually (while engine stopped)

5A–40
BRAKE CONTROL SYSTEM
Diagnosis By “ABS” Warning Light
Illumination Pattern
In the event that there is abnormality in the “ABS” warning
light illumination pattern while the key is in the ON position
or if the warning light is actuated during driving, trouble
should be diagnosed on a illumination pattern basis as
follows:
No.
Condition“ABS” Warning Light Illumination PatternDiagnostic
1Warning light is actu-
ated normallyNormal
2Warning light is not litWarning light lighting circuit
trouble
Go to Chart B-1
3Warning light remains
ONDiagnostic trouble codes are
stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to the
flow charts.
4Warning light is actu-
ated while drivingDiagnostic trouble codes are
stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to the
flow charts.
Diagnostic Trouble Codes (DTCs)
When the warning light in the meter remains ON, the
EHCU stores the fault identification and disables the
ABS.
1. How to display and erase DTCs:
NOTE:
If DTCs are not displayed, harness C-4 connector
terminal 30 and I-10 connector terminal 2 may be
disconnected. Repair the harness and try DTC
display again.
DTCs can be displayed also by TECH 2. Select mode
“F0: Diagnostic Trouble Codes” from Application
Menu.
1. How to start DTC display:
Confirm that the vehicle has come to a complete
stop (with the wheels standing still) and that the
brake pedal is not depressed. (Unless these two
conditions are satisfied, DTC display cannot be
started.)
With IGN OFF, connect #12 terminal with #4
terminal or # 5 terminal (GND) . Then turn IGN ON.

5A–41 BRAKE CONTROL SYSTEM
The DLC is located behind the center console
350RV010
Keep #12 terminal connected with #4 terminal or # 5
terminal (GND) during DTC display. (If #12 terminal
is separated from #4 terminal or # 5 terminal (GND)
during display, display will stop.)
2. DTC display:
DTC is displayed by blinking warning light.
Double-digit display.
First, normal DTC 12 is displayed three times and
then any other DTCs are displayed three times. (If
no other DTCs have been stored, the display of DTC
12 will be repeated.)
3. How to erase code:
Conduct brake switch ON/OFF operation 6 or more
times within 3 seconds of self-diagnosis startup.
The code cannot be erased if more than 3 seconds
have passed since self-diagnosis startup, or if
self-diagnosis has started with brake switched on
(brake pedal depressed).
B05RW005

6A–11
ENGINE MECHANICAL
Condition CorrectionPossible cause
Engine overheatingLevel of Engine Coolant too lowReplenish
Fan clutch defectiveReplace
Incorrect fan installedReplace
Thermostat defectiveReplace
Engine Coolant pump defectiveCorrect or replace
Radiator cloggedClean or replace
Radiator filler cap defectiveReplace
Level of oil in engine crankcase too
low or wrong engine oilChange or replenish
Resistance in exhaust system
increasedClean exhaust system or replace
defective parts
Throttle Position Sensor adjustment
incorrectReplace with Throttle Valve ASM
Throttle Position Sensor circuit open
or shortedCorrect or replace
Cylinder head gasket damagedReplace
Engine overcoolingThermostat defectiveReplace (Use a thermostat set to
open at 82
C (180F))
Engine lacks compression————Refer to Hard Start
OthersTire inflation pressure abnormalAdjust to recommended pressures
Brake dragAdjust
Clutch slippingAdjust or replace
Level of oil in engine crankcase too
highCorrect level of engine oil
Exhaust Gas Recirculation Valve
defectiveReplace
Engine Noisy
Abnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and othermoving parts of the engine. It is, therefore, advisable to
locate the source of noise systematically.
Condition
Possible causeCorrection
Noise from crank journals or from
crank bearings
(Faulty crank journals and crankOil clearance increased due to worn
crank journals or crank bearingsReplace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
yj
bearings usually make dull noise that
becomes more evident when
accelerating)Crankshaft out of roundReplace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
Crank bearing seizedCrank bearing seized. Replace crank
bearings and crankshaft or regrind
crankshaft and install the undersize
bearing
Troubleshooting Procedure
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defectivebearing by listening for abnormal noise that stops when
spark plug is shorted out.