1998 OPEL FRONTERA wiring

6E–181 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Lack of Power, Sluggish or Spongy Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Engine delivers less than expected power. Little or no
increase in speed when accelerator pedal is pushed
down part-way.
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/
Physical
Check
41. Remove and check the air filter element for dirt or
restrictions. Refer to
Air Intake System in
On-Vehicle Service.
2. Replace the air filter element if necessary.
Was a repair required?
—Verify repairGo to Step 5
51. Check AP sensor system. Refer to AP sensor
diagnostic
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 6
61. Check for water-or alcohol-contaminated fuel.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
71. Using a Tech 2, Injector test.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 8
81. Check the ECM grounds for the cleanliness,
tightness and proper locations. Refer to the ECM
wiring diagrams in
Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 9
91. 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 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 10
101. Check the torque converter clutch (TCC) for proper
operation. Refer to
Transmission Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 11

6E–183 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Rough, Unstable, or Incorrect Idle, Stalling Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Engine runs unevenly at idle. If severe, the engine or
vehicle may shake. Engine idle speed may vary in
RPM. Either condition may be severe enough to stall
the engine.
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?
—Go to Step 6Go to Step 3
3Was a visual/physical check performed?
—Go to Step 4
Go to Visual/
Physical
Check
41. Check the ECM grounds for cleanliness, tightness
and proper routing. Refer to the ECM wiring
diagrams in
Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 5
51. Check for incorrect idle speed. Ensure that the
following conditions are present:
The engine is fully warm.
The accessories are “OFF.”
2. Using a Tech 2, monitor the AP position.
Is the AP position within the specified values?
0%Go to Step 10Go to Step 9
61. Visually/physically inspect for the following
conditions:
Restricted air intake system. Check for a
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
71. Injector Test
Operate the each injector by Tech 2 with the
ignition “ON” and check if the working noise
confirm.
2. If a problem is found, check the harness or replace
the injector.
Is the action complete?
—Verify repairGo to Step 8
81. Check the transmission range switch circuit. Use a
Tech 2 and be sure the Tech 2 indicates that the
vehicle is in drive with the gear selector in drive or
overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary (Refer to
Automatic Transmission Diagnosis).
Was a problem found?
—Verify repairGo to Step 9

6E–189 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Cuts Out, Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Steady pulsation or jerking that follows engine speed;
usually more pronounced as engine load increases.
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?
—Go to Step 7Go to Step 3
3Was a visual/physical check performed?
—Go to Step 4
Go to Visual/
Physical
Check
41. Check the ECM grounds for clearness, tightness
and proper routing. Refer to the ECM wiring
diagrams in
Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 5
51. Check for incorrect idle speed. Ensure that the
following conditions are present:
The engine is fully warm.
The accessories are “off.”
2. Using a Tech 2, monitor the AP position.
Is the AP position within the specified values?
0%Go to Step 6Go to Step 7
61. Visually/physically inspect for the following
conditions:
Restricted air intake system. Check for a
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
Check the Throttle body.
Large vacuum leak. Check for a condition that
causes a large vacuum leak, such as an
incorrectly installed or faulty VSV or brake
booster hose disconnected .
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
7Using a Tech 2, monitor the AP angle with the engine
idling.
Is the AP angle at the specified value and steady?
0%Go to Step 8
Refer to DTC
P0123
for
further
diagnosis
81. Check the transmission range switch circuit. Use a
Tech 2 and be sure the Tech 2 indicates that the
vehicle is in drive with the gear selector in drive or
overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary.
Was a problem found?
—Verify repairGo to Step 9

6E–213 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
3. Connect the electrical connector to the AP sensor.
035RW060
4. Connect the negative battery cable.
Fuel Filter Cap
General Description
The fuel filler cap includes a vacuum valve and a pressure
valve.
If high vacuum or high pressure occurs in the fuel tank,
each valve works to adjust the pressure in order to
prevent damage to the tank at the EGR valve.
TS23767
Inspection Procedure
NOTE: Replace the fuel filler cap with the same type of
filler cap that was originally installed on the vehicle.
Check the seal ring in the filler cap for any abnormality
and for seal condition.
Replace the filler cap if any abnormality is found.
Fuel Filter
Removal and Installation Procedure
Refer to the Engine fuel in the 4JX1 Engine section.
Fuel Gauge Unit
Removal Procedure
1. Disconnect the negative battery cable.
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank.
Tighten
Tighten the drain plug to 20 Nꞏm (14 lb ft.).
TS22907
4. Disconnect the wiring connector from the fuel gauge
unit.
TS23771
5. Remove the fuel gauge unit retaining screws.

6E–214
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
6. Remove the fuel gauge unit.
Cover or plug the fuel tank to prevent dust, dirt, or
debris from entering the tank.
TS22911
Installation Procedure
1. Install the fuel gauge unit.
2. Install the fuel gauge unit retaining screws.
TS22911
3. Connect the wiring connector to the fuel gauge unit.
TS23771
4. Fill the fuel tank with fuel.
Tighten the fuel filler cap.
Check for leaks at the fuel gauge unit gasket.
5. Connect the negative battery cable.
Fuel Injectors
Removal and Installation Procedure
Refer to Engine Fuel in 4JX1 Engine Section.
Fuel Temperature Sensor
Removal Procedure
CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when servicing
fuel lines or connections. Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before disconnecting the fittings. The
towels will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
1. Disconnect the negative battery cable.
2. Remove the intercooler assembly.
3. Remove the cylinder head. Refer to engine
mechanical section.

6E–220
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Install the EVRV.
035RW064
2. Connect the EVRV hose and the EVRV connector.
035RW065
3. Connect the negative battery cable.
Wiring and Connectors
Wiring Harness Service
The ECM harness electrically connects the ECM to the
various solenoids, switches and sensors in the vehicle
engine compartment and passenger compartment.
Replace wire harnesses with the proper part number
replacement.
Because of the low amperage and voltage levels utilized
in powertrain control systems, it is essential that all wiring
in environmentally exposed areas be repaired with crimp
and seal splice sleeves.The following wire harness repair information is intended
as a general guideline only. Refer to
Chassis Electrical f o r
all wire harness repair procedures.
Connectors and Terminals
Use care when probing a connector and when replacing
terminals. It is possible to short between opposite
terminals. Damage to components could result. Always
use jumper wires between connectors for circuit
checking. NEVER probe through Weather-Pack seals.
Use an appropriate connector test adapter kit which
contains an assortment of flexible connectors used to
probe terminals during diagnosis. Use an appropriate
fuse remover and test tool for removing a fuse and to
adapt the fuse holder to a meter for diagnosis.
Open circuits are often difficult to locate by sight because
oxidation or terminal misalignment are hidden by the
connectors. Merely wiggling a connector on a sensor, or
in the wiring harness, may temporarily correct the open
circuit. Intermittent problems may also be caused by
oxidized or loose connections.
Be certain of the type of connector/terminal before
making any connector or terminal repair. Weather-Pack
and Com-Pack III terminals look similar, but are serviced
differently.
Wire Harness Repair: Twisted
Shielded Cable
Removal Procedure
1. Remove the outer jacket.
2. Unwrap the aluminum/mylar tape. Do not remove the
mylar.
047

6E–225 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
General Description
(ECM and Sensors)
57X Reference ECM Input
The engine control module (ECM) uses this signal from
the crankshaft position (CKP) sensor to calculate engine
RPM and crankshaft position at all engine speeds. The
ECM also uses the pulses on this circuit to initiate injector
pulses. If the ECM receives no pulses on this circuit, DTC
P0337 will set. The engine will not start and run without
using the 57X reference signal.
A/C Request Signal
This signal tells the ECM when the A/C mode is selected
at the A/C control head.
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 engine control module (ECM) to calculate the
ignition sequence. The CKP sensor initiates the 57X
reference pulses which the ECM uses to calculate RPM
and crankshaft position.
Refer to
Electronic Ignition System for additional
information.
Camshaft Position (CMP) Sensor and
Signal
The camshaft position (CMP) sensor sends a CMP signal
to the ECM. The ECM uses this signal as a “cylinder
distinction” to trigger the injectors in the power order. If the
ECM detects an incorrect CMP signal while the engine is
running, DTC P0341 will set, and the ECM triggers the
injectors in the power order.
Refer to
DTC P0341.
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 ECM supplies a 5-volt signal to the ECT sensor
through resistors in the ECM 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
ECM calculates the engine coolant temperature. Engine
coolant temperature affects most of the systems that the
ECM controls.
The 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 coolanttemperature and intake air temperature displays should
be close to each other. A hard fault in the engine coolant
sensor circuit will set DTC P0117 or DTC P0118.
0016
Electrically Erasable Programmable Read
Only Memory (EEPROM)
The electrically erasable programmable read only
memory (EEPROM) is a permanent memory chip that is
physically soldered within the ECM. The EEPROM
contains the program and the calibration information that
the ECM needs to control powertrain operation.
Unlike the PROM used in past applications, the EEPROM
is not replaceable. If the ECM is replaced, the new ECM
will need to be programmed. Equipment containing the
correct program and calibration for the vehicle is required
to program the ECM.
Intake Air Temperature (IAT) Sensor
The intake air temperature (IAT) sensor is a thermistor
which changes its resistance based on the temperature of
air entering the engine. Low temperature produces a high
resistance of 100,000 ohms at –40
C (–40F). High
temperature causes low resistance of 70 ohms at 130
C
(266
F) . The ECM supplies a 5-volt signal to the sensor
through a resistor in the ECM and monitors the signal
voltage. The voltage will be high when the incoming air is
cold. The voltage will be low when the incoming air is hot.
By measuring the voltage, the ECM calculates the
incoming air temperature.
The Tech 2 displays the temperature of the air entering
the engine. The temperature should read close to the
ambient air temperature when the engine is cold and rise
as underhood temperature increases. If the engine has
not been run for several hours (overnight), the IAT sensor
temperature and engine coolant temperature should read
close to each other. A fault in the IAT sensor circuit will set
DTC P0112 or DTC P0113.

6E–228
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
General Description (Air Induction)
Air Induction System
The air induction system filters contaminants from the
outside air, and directs the progress of the air as it is
drawn into the engine. A remote-mounted air cleaner
prevents dirt and debris in the air from entering the
engine. The air duct assembly routes filtered air to the
throttle body. Air enters the engine by to following steps:
1. Through the throttle body.
2. Into the intake manifold.
3. Through the cylinder head intake ports.
4. Into the cylinders.
General Description (Fuel Metering)
Deceleration Mode
The ECM reduces the amount of fuel injected when it
detects a decrease in the Accelerator position.
Fuel Injector
Fuel injector comprises the solenoid, hydraulic line, and
fuel line. Fuel injection is controlled by the continuity time
signal and continuity start timing signal from ECM to the
solenoid
ECM determines the running conditions of engine by
input signals such as engine speed. Accelerator throttle
valve opening, and engine coolant temperature, thereby
to send the solenoid the best suited signal to the engine
status. When current is carried to the solenoid, the
armature opens the poppet valve to alow high pressure oil
to run into the injector. Under the pressure of the oil, the
piston and plunger are depressed to compress the fuel in
the combustion chamber of the plunger. Specifically, the
pressure of the fuel compressed is increased by a piston
top/ plunger bottom area ratio over the pressure of high
pressure oil, thereby lifting the fuel nozzle end needle for
injecting fuel.
Fuel Metering System Components
The fuel metering system is made up of the following
parts:
The fuel injectors.
The intake throttle body.
The Accelerator position (AP) sensor
The ECM.
The crankshaft position (CKP) sensor.
The camshaft position (CMP) sensor.
Basic System Operation
Fuel is supplied through fuel filter to the fuel pump.
The fuel pump is installed to the oil pump, and fuel is
forced, through the fuel pump outlet, pipe and cylinder
head inside, into the fuel injector.
An orifice is provided at the rear fuel outlet of cylinder
head to control the pressure of oil.The injector is controlled by ECM which gives
opening/closing commands to the solenoid installed on
the top of the injector. Opening/closing operation of the
pressurized engine oil circuit of the injector controls fuel
injection quantity, fuel injection timing, etc.
A/C Clutch Diagnosis
A/C Request Signal
This signal tells the ECM when the A/C mode is selected
at the A/C control head. The ECM uses this to adjust the
idle speed.
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.
The ECM uses information from the following sensors to
control EGR valve boost pressure.
ECT
ITP
Engine Speed
AP sensor