1998 OPEL FRONTERA fuse

ENGINE MECHANICAL 6A – 13
VALVE CLEARANCE ADJUSTMENT
1. Install 2.80 mm valve adjuster (shim) first when
reassembling the engine.
Thickness mark faces down.
2. Measure the valve clearance after installing cam
carrier assy with camshafts.
3. Change the adjuster using a special tool when the
clearance is out of tolerance.
Valve Clearance Adjusting Tool: 5-8840-2590-0
VALVE CLEARANCE (When cold condition)
Inlet 0.15 ± 0.05 mm
Exh 0.25 ± 0.05 mm
COMPRESSION PRESSURE
MEASUREMENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 – 80°C (158 – 176°F).
2. Remove the following parts.
Glow plugs
Fuel cut solenoid connector
QOS (Quick-On Start System) fuse in the fuse
box.
3. Set the adapter and compression gauge to the No.
1 cylinder glow plug hole.
Compression Gauge
(with Adapter): 5-8840-2008-0
4. Turn the engine over with the starter motor and take
the compression gauge reading.
Compression Pressure at 200 rpm
Standard: 3038 kPa (31 kg/cm
2/441 psi)
Limit: 2157 kPa (22 kg/cm
2/313 psi)
5. Repeat the procedure (Steps 3 and 4) for the
remaining cylinders.
QUICK-ON START 4 SYSTEM
Quick-On Start System Inspection Procedure
1. Disconnect the ECT-sensor connection around the
thermostat outlet pipe.
2. Turn the starter switch to the “ON” position.
If the Quick-On Start 4 System is operating
properly, the glow relay will make a clicking sound
within seven seconds after the starter switch is
turned on.
3. Measure the glow plug terminal voltage with a
circuit tester immediately after turning the starter
switch to the “ON” position.
Glow Plug Terminal Voltage: 8 – 9V
NOTE: Electrical power to the quick-on start system will
be cut after the starter has remained in the “ON”
position for twenty seconds.
Turn the starter switch to the “OFF” position and back
to the “ON” position.
This will reset the Quick-On Start 4 System.
014RW150

ENGINE ELECTRICAL 6D – 1
ENGINE ELECTRICAL
CONTENTS
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–1
General Description . . . . . . . . . . . . . . . . 6D–1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 6D–1
On Vehicle Service . . . . . . . . . . . . . . . . . 6D–3
Main Data and Specification . . . . . . . . . . 6D–4
Starting System . . . . . . . . . . . . . . . . . . . . . 6D–5
General Description . . . . . . . . . . . . . . . . 6D–5
On Vehicle Service . . . . . . . . . . . . . . . . . 6D–7
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–7
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 6D–8Charging System . . . . . . . . . . . . . . . . . . . . 6D–15
General Description . . . . . . . . . . . . . . . . 6D–15
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 6D–16
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 6D–17
Main Data and Specification . . . . . . . . . . 6D–22
QOS4 Preheating System . . . . . . . . . . . . . . 6D–23
General Description . . . . . . . . . . . . . . . . 6D–23
System Diagram . . . . . . . . . . . . . . . . . . . 6D–23
Inspection of QOS4 System Operation . . 6D–24
BATTERY
GENERAL DESCRIPTION
DIAGNOSIS
There are six battery fluid caps at the top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six
small vent holes at the side. These vent holes permit
the escape of small amounts of gas generated by the
battery.
This type of battery has the following advantages over
conventional batteries:1. There is no need to add water during the entire
service life of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an excessive
charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery
fluid.)
3. The battery is much less vulnerable to self-
discharge than a conventional type battery.
1. VISUAL INSPECTION (Step 1)
Inspect the battery for obvious physical damage, such
as a cracked or broken case, which would permit
electrolyte loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it as
necessary. If not, proceed to Step 2.
2. HYDROMETER CHECK (Step 2)
There is a built-in hydrometer (Charge test indicator) at
the top of the battery. It is designed to be used during
diagnostic procedures.
Before trying to read the hydrometer, carefully clean the
upper battery surface.
If your work area is poorly lit, additional light may be
necessary to read the hydrometer.
a. BLUE RING OR DOT VISIBLE – Go to Step 4.
b. BLUE RING OR DOT NOT VISIBLE – Go to
Step 3.3. FLUID LEVEL CHECK (Step 3)
The fluid level should be between the upper level line
and lower level line on side of the battery.
a. CORRECT FLUID LEVEL – Charge the battery.
b. BELOW LOWER LEVEL – Replace battery.
4. VOLTAGE CHECK (Step 4)
(1) Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE – Go to Step 5.
b. VOLTAGE IS UNDER 12.4V – Go to procedure
(2) below.
(2) Determine fast charge amperage from
specification. (See Main Data and Specifications in
this section.)
Fast charge battery for 30 minutes at amperage
rate no higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE – Replace battery.

6E–6
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Removal Procedure 6E–212. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–212. . . . . . . . . . . . . . . . . .
Fuel Filter Cap 6E–213. . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6E–213. . . . . . . . . . . . . . . . . . . .
Inspection Procedure 6E–213. . . . . . . . . . . . . . . . . .
Fuel Filter 6E–213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation Procedure 6E–213. . . . . .
Fuel Gauge Unit 6E–213. . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–213. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–214. . . . . . . . . . . . . . . . . .
Fuel Injectors 6E–214. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation Procedure 6E–214. . . . . .
Fuel Temperature Sensor 6E–214. . . . . . . . . . . . . . . .
Removal Procedure 6E–214. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–215. . . . . . . . . . . . . . . . . .
Rail Pressure (RP) Sensor 6E–216. . . . . . . . . . . . . . .
Removal Procedure 6E–216. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–216. . . . . . . . . . . . . . . . . .
Fuel Tank 6E–216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–216. . . . . . . . . . . . . . . . . . . .
Throttle Body (TB) 6E–217. . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–217. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–217. . . . . . . . . . . . . . . . . .
Air Conditioning (A/C) Relay 6E–217. . . . . . . . . . . . . .
Removal Procedure 6E–217. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–217. . . . . . . . . . . . . . . . . .
Exhaust Gas Recirculation (EGR) Vacuum
Switch Valve (VSV) 6E–217. . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–217. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–218. . . . . . . . . . . . . . . . . .
Electronic Vacuum Regurating Valve (EVRV) 6E–219
Removal Procedure 6E–219. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–220. . . . . . . . . . . . . . . . . .
Wiring and Connectors 6E–220. . . . . . . . . . . . . . . . . . .
Wiring Harness Service 6E–220. . . . . . . . . . . . . . . .
Connectors and Terminals 6E–220. . . . . . . . . . . . . .
Wire Harness Repair: Twisted Shielded
Cable 6E–220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–220. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–221. . . . . . . . . . . . . . . . . .
Twisted Leads 6E–221. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–221. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–222. . . . . . . . . . . . . . . . . .
Weather-Pack Connector 6E–223. . . . . . . . . . . . . . . . .
Tools Required 6E–223. . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–223. . . . . . . . . . . . . . . . . . . . Installation Procedure 6E–223. . . . . . . . . . . . . . . . . .
Com-Pack III 6E–224. . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 6E–224. . . . . . . . . . . . . . . . . . . .
Metri-Pack 6E–224. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools Required 6E–224. . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure 6E–224
. . . . . . . . . . . . . . . . . . . .
Installation Procedure 6E–224. . . . . . . . . . . . . . . . . .
General Description
(ECM and Sensors) 6E–225. . . . . . . . . . . . . . . . . . . . .
57X Reference ECM Input 6E–225. . . . . . . . . . . . . .
A/C Request Signal 6E–225. . . . . . . . . . . . . . . . . . . .
Crankshaft Position (CKP) Sensor 6E–225. . . . . . .
Camshaft Position (CMP) Sensor and
Signal 6E–225. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature (ECT) Sensor 6E–225
Electrically Erasable Programmable Read
Only Memory (EEPROM) 6E–225. . . . . . . . . . . . . .
Intake Air Temperature (IAT) Sensor 6E–225. . . . .
Manifold Absolute Pressure (MAP) Sensor 6E–226
Engine Control Module (ECM) 6E–226. . . . . . . . . . .
ECM Function 6E–226. . . . . . . . . . . . . . . . . . . . . . . . .
ECM Components 6E–226. . . . . . . . . . . . . . . . . . . . .
ECM Voltage Description 6E–226. . . . . . . . . . . . . . .
ECM Input/Outputs 6E–226. . . . . . . . . . . . . . . . . . . .
ECM Service Precautions 6E–227. . . . . . . . . . . . . .
Intake Throttle Position (ITP) Sensor 6E–227. . . . .
Transmission Range Switch 6E–227. . . . . . . . . . . . .
Accelerator Position Sensor (AP) 6E–227. . . . . . . .
Aftermarket Electrical and Vacuum
Equipment 6E–227. . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Damage 6E–227. . . . . . . . .
General Description (Air Induction) 6E–228. . . . . . . .
Air Induction System 6E–228. . . . . . . . . . . . . . . . . . .
General Description (Fuel Metering) 6E–228. . . . . . .
Deceleration Mode 6E–228. . . . . . . . . . . . . . . . . . . .
Fuel Injector 6E–228. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Metering System Components 6E–228. . . . . .
A/C Clutch Diagnosis 6E–228. . . . . . . . . . . . . . . . . . . .
A/C Request Signal 6E–228. . . . . . . . . . . . . . . . . . . .
General Description Exhaust Gas
Recirculation (EGR) System 6E–228. . . . . . . . . . . . .
EGR Purpose 6E–228. . . . . . . . . . . . . . . . . . . . . . . . .
Fuse and Relay Panel
(Underhood Electrical Center) RHD 6E–229. . . . . . .
Fuse and Relay Panel
(Underhood Electrical Center) LHD 6E–230. . . . . . .

6E–28
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
in the ECM’s memory, the DTC(s) will be output from the
lowest to the highest, with each DTC being displayed
three times.
The DTC display will continue as long as the DLC is
shorted.
Reading Diagnostic Trouble Codes Using
a TECH 2
The procedure for reading diagnostic trouble code(s) is to
used a diagnostic Tech 2. When reading DTC(s), follow
instructions supplied by Tech 2 manufacturer.
For the 1998 model year, Isuzu dealer service
departments will continue to use Tech 2.
Clearing Diagnostic Trouble Codes
IMPORTANT:Do not clear DTCs unless directed to do
so by the service information provided for each diagnostic
procedure. When DTCs are cleared, the Freeze Frame
and Failure Record data which may help diagnose an
intermittent fault will also be erased from memory.
If the fault that caused the DTC to be stored into memory
has been corrected, the Diagnostic Executive will begin to
count the “warm-up” cycles with no further faults
detected, the DTC will automatically be cleared from the
ECM memory.To clear Diagnostic Trouble Codes (DTCs), use the Tech
2 “clear DTCs” or “clear information” function. When
clearing DTCs follow instructions supplied by the Tech 2
manufacturer.
When a Tech 2 is not available, DTCs can also be cleared
by disconnecting
one of the following sources for at least
thirty (30) seconds.
NOTE: To prevent system damage, the ignition key must
be “OFF” when disconnecting or reconnecting battery
power.
The power source to the control module. Examples:
fuse, pigtail at battery ECM connectors etc.
The negative battery cable. (Disconnecting the
negative battery cable will result in the loss of other
on-board memory data, such as preset radio tuning).
060RW169

6E–44
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
No Malfunction Indicator Lamp (MIL)
060RW136
Circuit Description
The “Check Engine” lamp (MIL) should always be
illuminated and steady with the ignition “ON” and the
engine stopped. Ignition feed voltage is supplied to the
MIL bulb through the meter fuse. The Engine Control
Module ECM turns the MIL “ON” by grounding the MIL
driver circuit.
Diagnostic Aids
An intermittent MIL may be cause by a poor connection,
rubbed-through wire insulation, or a wire broken inside
the insulation. Check for the following items:
Inspect the ECM harness and connections for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire
connection, and damaged harness.
If the engine runs OK, check for a faulty light bulb, an
open in the MIL driver circuit, or an open in the
instrument cluster ignition feed.
If the engine cranks but will not run, check for an open
ECM ignition or battery feed, or a poor ECM to engine
ground.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
2. A “No MIL” condition accompanied by a no-start
condition suggests a faulty ECM ignition feed or
battery feed circuit.
9. Using a test light connected to B+, probe each of the
ECM ground terminals to ensure that a good ground
is present. Refer to
ECM Terminal End View for
terminal locations of the ECM ground circuits.
12.In this step, temporarily substitute a known good
relay for the ECM relay. The horn relay is nearby,
and it can be verified as “good” simply by honking
the horn. Replace the horn relay after completing
this step.

6E–45 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
No Malfunction Indicator Lamp (MIL)
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
2Attempt to start the engine.
Does the engine start?
—Go to Step 3Go to Step 6
3Check the meter fuse for the instrument cluster ignition
feed circuit.
Is the fuse OK?
—Go to Step 4Go to Step 16
4Ignition “ON,” probe the ignition feed circuit at the
cluster connector with a test light to ground.
Is the test light “ON?”
—Go to Step 5Go to Step 13
51. Ignition “OFF.”
2. Disconnect the ECM.
3. Jumper the MIL driver circuit at the ECM connector
to ground.
4. Ignition “ON.”
Is the MIL “ON?”
—Go to Step 10Go to Step 11
6Check the ECM ignition feed and battery feed fuses (15
A engine fuse and 15 A ECM fuse).
Are both fuses OK?
—Go to Step 7Go to Step 15
71. Ignition “OFF.”
2. Disconnect the ECM.
3. Ignition “ON.”
4. Probe the ignition feed circuit at the ECM harness
connector with a test light to ground.
Is the test light “ON?”
—Go to Step 8Go to Step 12
8Probe the battery feed circuit at the ECM harness
connector with a test light to ground.
Is the test light “ON?”
—Go to Step 9Go to Step 14
9Check for a faulty ECM ground connection.
Was a problem found?
—Verify repairGo to Step 10
10Check for damaged terminals at the ECM.
Was a problem found?
—Verify repairGo to Step 17
11Check for an open MIL driver circuit between the ECM
and the MIL.
Was a problem found?
—Verify repairGo to Step 18
12Substitute a known “good” relay for the ECM main
relay.
Was the malfunction fixed?
—Verify repairGo to Step 13
13Repair the open in the ignition feed circuit.
Is the action complete?
—Verify repair—
14Locate and repair the open ECM battery feed circuit.
Is the action complete?
—Verify repair—

6E–46
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
No Malfunction Indicator Lamp (MIL)
StepNo Ye s Va l u e ( s ) Action
15Locate and repair the short to ground in the ECM
ignition feed circuit or ECM battery feed circuit.
Is the action complete?
—Verify repair—
16Locate and repair the short to ground in the ignition
feed circuit to the instrument cluster, and replace the
fuse.
Is the action complete?
—Verify repair—
17Replace the ECM (Refer to the Data Programming in
Case of ECM change).
Is the action complete?
—Verify repair—
18Check the MIL driver circuit for a poor connection at the
instrument panel connector.
Was a problem found?
—Verify repair
Go to
Instrument
Panel
in
Electrical
Diagnosis

6E–49 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Engine Cranks But Will Not Run
Circuit Description
In this type of injector system, the Engine Control Module
(ECM) triggers the correct driver inside the injector, which
then triggers the correct injector based on the 57X signal
received from the crankshaft position sensor (CKP).
During crank, the ECM monitors the CKP 57X signal. The
CKP signal is used to determine which cylinder will fire
first. After the CKP 57X signal has been processed by the
ECM, it will command all four injectors to allow a priming
shot of fuel for all the cylinders. After the priming, the
injectors are left “OFF” during the next four 57X reference
pulses from the CKP. This allows each cylinder a chance
to use the fuel from the priming shot. During this waiting
period, a camshaft position (CMP) signal pulse will have
been received by the ECM. The CMP signal allows the
ECM to operate the injectors sequentially based on
camshaft position. If the camshaft position signal is not
present at start-up, the ECM will begin sequential fuel
delivery with a 1-in-4 chance that fuel delivery is correct.
The engine will run without a CMP signal, but will set a
DTC code.
Diagnostic Aids
An intermittent problem may be caused by a poor
connection, rubbed-through wire insulation or a wirebroken inside the insulation. Check for the following
items:
Poor connection or damaged harness – Inspect the
ECM harness and connectors for improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal-to-wore connection, and
damaged harness.
Faulty engine coolant temperature sensor – Using a
Tech 2, compare engine coolant temperature with
manifold air temperature on a completely cool engine.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
4. An obvious cause of low fuel pressure would be an
empty fuel tank.
5. The engine will easily start and run if a few injectors
are disabled. It is not necessary to test all injectors
at this time since this step is only a test to verify that
all of the injectors have not been disabled by fuel
contamination.
8.If there is an open or shorted driver circuit, DTCs
0201-0204 should be set.
Engine Cranks But Will Not Run
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
2Check the 15 A injector fuse, the 15 A engine device
fuse, and the 15A ECM fuse.
Was a fuse blown?
—Go to Step 3Go to Step 4
3Check for a short to ground and replace the fuse.
Is the action complete?
—Verify repair—
4Is fuel tank empty?
—
Fill the fuel
tank
Go to Step 5
5Is the right fuel using?
—Go to Step 6
Replace the
fuel
6Is the right engine oil using?
—Go to Step 7
Replace the
engine oil
7Using the Tech–2.
Is DTC P0192 or P0193 set? (Check rail pressure
system)
—
Go to DTC
P0192 or
DTC P0193
Go to Step 8
8Using the Tech–2.
Is DTC P0201 – P0204 set? (Check inject circuit fault)
—
Go to DTC
P0201 –
P0204
Go to Step 9
9Using the Tech–2.
Is DTC P1657 set? (Check ECM Main relay)
—
Go to DTC
P1657
Go to Step 10