1998 OPEL FRONTERA seat

6E–60
ENGINE DRIVEABILITY AND EMISSIONS
Electronic Ignition System Diagnosis
If the engine cranks but will not run or immediately stalls,
the Engine Cranks But Will Not Start chart must be used
to determine if the failure is the ignition system or the fuel
system. If DTC P0341, or P0336 is set, the appropriate
diagnostic trouble code chart must be used for diagnosis.
If a misfire is being experienced with no DTC set, refer to
the
Symptoms section for diagnosis.
Fuel Metering System Check
Some failures of the fuel metering system will result in an
“Engine Cranks But Will Not Run” symptom. If this
condition exists, refer to the
Cranks But Will Not Run
chart. This chart will determine if the problem is caused
by the ignition system, the PCM, or the fuel pump
electrical circuit.
Refer to
Fuel System Electrical Test for the fuel system
wiring schematic.
If there is a fuel delivery problem, refer to
Fuel System
Diagnosis
, which diagnoses the fuel injectors, the fuel
pressure regulator, and the fuel pump. If a malfunction
occurs in the fuel metering system, it usually results in
either a rich HO2S signal or a lean HO2S signal. This
condition is indicated by the HO2S voltage, which causes
the PCM to change the fuel calculation (fuel injector pulse
width) based on the HO2S reading. Changes made to the
fuel calculation will be indicated by a change in the long
term fuel trim values which can be monitored with a Tech
2. Ideal long term fuel trim values are around 0%; for a
lean HO2S signal, the PCM will add fuel, resulting in a fuel
trim value above 0%. Some variations in fuel trim values
are normal because all engines are not exactly the same.
If the fuel trim values are greater than +23%, refer to
DTC
P0131, DTC P0151, DTC P0171, and DTC 1171
f o r i t e m s
which can cause a lean HO2S signal.
Idle Air Control (IAC) Valve
The Tech 2 displays the IAC pintle position in counts. A
count of “0” indicates the PCM is commanding the IAC
pintle to be driven all the way into a fully-seated position.
This is usually caused by a large vacuum leak.
The higher the number of counts, the more air is being
commanded to bypass the throttle blade. Refer to IAC
System Check in order to diagnose the IAC system.
Refer to
Rough, Unstable, or Incorrect Idle, Stalling in
Symptoms for other possible causes of idle problems.
Fuel System Pressure Test
A fuel system pressure test is part of several of the
diagnostic charts and symptom checks. To perform this
test, refer to
Fuel Systems Diagnosis.
Fuel Injector Coil Test Procedure and
Fuel Injector Balance Test Procedure
T32003
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart:
2. Relieve the fuel pressure by connecting the
5-8840-0378-0 Fuel Pressure Gauge to the fuel
pressure connection on the fuel rail.
CAUTION: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the fuel
pressure connection. The towel will absorb any fuel
leakage that occurs during the connection of the fuel
pressure gauge. Place the towel in an approved
container when the connection of the fuel pressure
gauge is complete.
Place the fuel pressure gauge bleed hose in an
approved gasoline container.
With the ignition switch “OFF,” open the valve on the
fuel pressure gauge.
3. Record the lowest voltage displayed by the DVM
after the first second of the test. (During the first
second, voltage displayed by the DVM may be
inaccurate due to the initial current surge.)
Injector Specifications:
Resistance Ohms
Voltage Specification at
10
C-35C (50F-95F)
11.8 – 12.65.7 – 6.6
The voltage displayed by the DVM should be within
the specified range.
The voltage displayed by the DVM may increase
throughout the test as the fuel injector windings
warm and the resistance of the fuel injector windings
changes.

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.

6E–93 ENGINE DRIVEABILITY AND EMISSIONS
Idle Air Control (IAC) System Check
Circuit Description
The powertrain control module (PCM) controls engine
idle speed with the idle air control (IAC) valve. To increase
idle speed, the PCM retracts the IAC valve pintle away
from its seat, allowing more air to bypass the throttle bore.
To decrease idle speed, it extends the IAC valve pintle
towards its seat, reducing by pass air flow. Tech 2 will
read the PCM commands to the IAC valve in counts.
Higher counts indicate more air bypass (higher idle).
Lower counts indicate less air is allowed to bypass (lower
idle).
Diagnostic Aids
A slow, unstable, or fast idle may be caused by a non-IAC
system problem that cannot be overcome by the IAC
valve. Out of control range IAC Tech 2 counts will be
above 60 if idle is too low, and zero counts if idle is too
high. The following checks should be made to repair a
non-IAC system problem:
Vacuum leak (high idle) – If idle is too high, stop the
engine. Fully extend (low) IAC with the Tech 2. Start
the engine. If idle speed is above 800 RPM, locate and
correct the vacuum leak, including the PCV system.
Check for binding of the throttle blade or linkage.
Lean heated oxygen sensor signal (high air/fuel ratio) –
The idle speed may be too high or too low. Engine
speed may vary up and down, and disconnecting the
IAC valve does not help. Diagnostic trouble codes
P0131, P0151, P0171, or P0174 may be set. Tech 2
oxygen (O2) voltage will be less than 100 mV (0.1 V).
Check for low regulated fuel pressure, water in fuel, or
a restricted injector.
Rich heated oxygen sensor signal (low air/fuel ratio) –
The idle speed will be too low. Tech 2 IAC counts will
usually be above 80. The system is obviously rich and
may exhibit black smoke in the exhaust.
Tech 2 O2 voltage will be fixed at about 750 mV (0.75
V). Check for high fuel pressure, or a leaking or
sticking injector. A silicon-contaminated heated
oxygen sensor will show an O2 voltage slow to
respond on Tech 2.
Throttle body – Remove the IAC valve and inspect the
bore for foreign material.
IAC valve electrical connections – IAC valve
connections should be carefully checked for proper
contact.
PCV valve – An incorrect or faulty PCV valve may
result in an incorrect idle speed. Refer to
Diagnosis,
Rough Idle, Stalling.
If intermittent poor driveability or
idle symptoms are resolved by disconnecting the IAC,
carefully recheck the connections and valve terminal
resistance, or replace the IAC.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
1. The Tech 2 is used to extend and retract the IAC
valve. Valve movement is verified by an engine
speed change. If no change in engine speed
occurs, the valve can be resettled when removed
from the throttle body.
2. This step checks the quality of the IAC movement in
step 1. Between 700 revolutions per minute (RPM)
and about 1500 RPM, the engine speed should
change smoothly with each flash of the tester light
in both extend and retract. If the IAC valve is
retracted beyond the control range (about 1500
RPM), it may take many flashes to extend the IAC
valve before engine speed will begin to drop. This
is normal on certain engines. Fully extending the
IAC may cause engine stall. This may be normal.

6E–105 ENGINE DRIVEABILITY AND EMISSIONS
The engine oil dip stick not fully seated.
The engine oil fill cap loose or missing.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
2. The MAF system performance or “rationality”
diagnostic uses the MAP sensor signal along with
other input to calculate an expected airflow rate that
is then compared to the actual measured airflow
from the MAF sensor. The first few steps of this
table verify that the MAP sensor is working properly.
6. Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If the
DTC cannot be duplicated, the information included
in the Freeze Frame and/or Failure Records data
can be useful in determining how many miles since
the DTC set. The Fail Counter and Pass Counter
can also be used to determine how many ignition
cycles the diagnostic reported a pass and/or a fail.
Operate the vehicle within the same Freeze Frame
conditions (RPM, load, vehicle speed , temperature,
etc.) that were noted. This will isolate when the
DTC failed.For any test that requires back probing the PCM or
component harness connectors, use the Connector
Test Adapter Kit J 35616-A. Using this kit will
prevent any damage to the harness connector
terminals.
7. Any un-metered air may cause this DTC to set.
Check the PVC system for vacuum leaks. Also
inspect the dip stick for being pulled out. Check the
oil fill cap for being loose.
8. Verifies the signal circuit from the MAF sensor
electrical connector to the PCM.
9. Verifies whether a ground and B+ circuit is available.
10. Checks a signal circuit for an open.
11. Checks for a signal circuit shorted to B+.
DTC P0101 – MAF System Performance
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 “OFF.”
2. Using a Tech 2, select “MAP” from the Engine 1
Data List.
Is the value displayed greater than the value shown?
85 kPaGo to Step 3Go toStep 13
31. Remove the MAP sensor from the intake manifold
but leave the electrical harness connected.
2. Connect a hand operated vacuum pump to the MAP
sensor.
3. Observe the MAP display while slowly applying
vacuum up to 20” Hg as indicated on the pump
gauge.
Each 1” of vacuum applied should result in a 3 to 4 kPa
drop in the MAP sensor value on the Tech 2 and the
value should change smoothly with each increase in
vacuum.
Did the MAP value change smoothly through the entire
range of the test without any erratic readings?
—Go to Step 13Go to Step 4
4With 20” Hg vacuum applied to the MAP sensor, is the
MAF sensor reading the same or less than the value
shown?
34 kPaGo to Step 5Go to Step 13
5Disconnect the vacuum source from the MAP sensor.
Does the MAP sensor reading return to its original
value?
—Go to Step 6Go to Step 13

6E–224
ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error
D06RW106
Circuit Description
The powertrain control module (PCM) monitors the EGR
valve pintle position input to ensure that the valve
responds properly to commands from the PCM, and to
detect a fault if pintle position is stuck open. If the PCM
detects a pintle position signal indicates more than 21.5%
and more than for 625 msec during cranking, the PCM will
set DTC P0402.
Conditions for Setting the DTC
Ignition voltage is between 11 and 16 volts.
Intake Air temp is more than 3C
At Engine revolution less than 600 RPM, EGR pintle
position indicates more than 21.5% and more than for
625 msecs.
Action Taken When the DTC Sets
The PCM will illuminate the malfunction indicator lamp
(MIL) after the second consecutive trip in which the
fault is detected.
The PCM will store conditions which were present
w h e n t h e D T C w a s s e t a s F r e e z e F r a m e a n d i n F a i l u r e
Records data.
Conditions for Clearing the MIL/DTC
DTC P0402 can be cleared by using Tech 2 “Clear Info”
function or by disconnecting the PCM battery feed.
Diagnostic Aids
Check for the following conditions:
Foreign material on EGR valve between pintle and
seat may cause EGR stuck open. Inspect foreign
material in EGR valve.
Excessive carbon deposit may cause unsmooth
operation of EGR valve shaft. Inspect carbon deposit
and clean up inside of carbon deposit.
Poor connection or damaged harness–inspect the
wiring harness for damage If the harness appears to be
OK, observe the EGR actual position display on Tech
2 while moving connectors and wiring harnesses
related to EGR valve. A change in the display will
indicate the location of the fault.
NOTE: If the EGR valve shows signs of excessive heat,
check the exhaust system for blockage (possibly a
plugged catalytic converter) using the “Restricted
Exhaust System Check”.

6E–225 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0402 – EGR Pintle Crank Open Error
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 “OFF”, review and record
Tech 2 Failure Records data.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using Tech 2, monitor “Specific DTC” info for DTC
P0402 until the DTC P0402 test runs. Note the
result.
Does Tech 2 indicates DTC P0402 failed this ignition?
—Go to Step 3
Refer to
Diagnostic
Aids
31. Disconnect the EGR valve harness connector.
2. Inspect the EGR valve and connectors for damaged
pin or terminals.
Were there any damaged pins or terminals?
—Go to Step 4Go to Step 5
4Repair the damaged pin or terminal.
Is the action complete?
—Verify repair—
51. Remove EGR valve from Engine.
2. Inspect EGR valve whether there is any foreign
material between seat and pintle.
Was any foreign material in EGR valve?
—Go to Step 6Go to Step 7
61. Remove EGR valve foreign material from EGR
valve and clean up inside.
2. Visually inspect damage of pintle and seat, which
leakage may occur.
Was there any severe damage which affects function?
—Go to Step 7
Verify repair
Go to
Step 8
71. Reconnect.
2. Ignition “OFF”.
3. Install Tech 2.
4. Run the engine at idle.
5. On Tech-II, select special function for EGR.
6. Use the “UP” arrow to increase the EGR from 0% to
40%.
Did EGR work properly?
——Go to Step 8
8Replace the EGR valve.
Does DTC P0402 still fail “DTC” test on Tech 2?
—Go to Step 9Verify repair
9Replace the EGR valve.
Is the action complete?
—Verify repair—

6E–227 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0404 – EGR Open Stuck
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 “OFF”, review and record
Tech 2 Failure Records Data.
2. Operate the vehicle within Failure Records
conditions as noted.
3. Using Tech 2, monitor “Specific DTC” info for DTC
P0404 until the DTC P0404 test runs. Note the
result.
Does Tech 2 indicates DTC P0404 failed this ignition?
—Go to Step 3
Refer to
Diagnostic
Aids
31. Disconnect the EGR valve harness connector.
2. Inspect the EGR valve and connectors for damaged
pin or terminals.
Were there any damaged pins or terminals?
—Go to Step 4Go to Step 5
4Repair the damaged pin or terminal.
—Verify repair
Is the action
complete?
51. Remove EGR valve from Engine.
2. Inspect EGR valve whether there is any excessive
carbon deposit on EGR shaft.
Was excessive carbon deposit 0n EGR valve shaft?
—Go to Step 6Go to Step 7
61. Clean up EGR valve shaft and inside of EGR valve.
2. Visually inspect damage of pintle and seat whether
there is bent, leakage may occur.
Was there any severe damage which affects function?
—Go to Step 8
Verify repair
Go to
Step 7
71. Reconnect.
2. Ignition “OFF”.
3. Install Tech 2.
4. Run the engine at idle.
5. On Tech 2, select F3:Misc. Test; F2:EGR.
6. Use the “UP” arrow to increase the EGR from 0% to
40%.
Did EGR work properly?
——Go to Step 8
8Replace the EGR valve.
Does DTC P0404 still fail “DTC” test on Tech 2?
—Go to Step 9Verify repair
9Replace the PCM.
IMPORTANT:The replacement PCM must be
programmed. Refer to
UBS 98model year Immobilizer
Workshop Manual.
Is the action complete?—Verify repair—

6E–249 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1404 EGR Closed Stuck
D06RW106
Circuit Description
The powertrain control module (PCM) monitors the EGR
valve pintle position input to ensure that the valve
responds properly to commands from the PCM, and to
detect a fault if current pintle zero position is different from
the learned zero position. If the PCM detects a pintle
position signal indicates more than 30 % different
between current zero position and the learned zero
position and more than 5 seconds, and this condition
meet 3 times during trip, then the PCM will set DTC
P1404.
Conditions for Setting the DTC
Ignition voltage is between 11 and 16 volts.
Intake Air temp is more than 3C.
Desire EGR position is 0.
Difference EGR pintle position between current and
the learned zero is more than 30 % last more than 5
seconds, and meet three time to the above condition
during a trip. Then it trigger the PCM lights on.
Action Taken When the DTC Sets
The PCM will illuminate the malfunction indicator lamp
(MIL) after consecutive 2nd trip in which the fault is
detected.
The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in Failure
Records data.
Conditions for Clearing the MIL/DTC
DTC P1404 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids
Check for the following conditions:
Excessive carbon deposit on EGR valve shaft or/and
foreign material may cause no return to EGR valve
fully seated. Those carbon deposit may occur by
unusual port operation. Remove foreign material
or/and excessive carbon deposit on EGR valve shaft
may make return to EGR valve fully seated.
Poor connection or damaged harness – Inspect the
wiring harness for damage. Same as P1406
description
Reviewing the Failure Records vehicle mileage since the
diagnostic test last failed may help determine how often
the condition that caused the DTC to be set occurs. This
may assist in diagnosing the condition.