1998 OPEL FRONTERA fuel cap

6E–345 ENGINE DRIVEABILITY AND EMISSIONS
0014
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor provides a signal
used by the powertrain control module (PCM) to calculate
the ignition sequence. The sensor initiates the 58X
reference pulses which the PCM uses to calculate RPM
and crankshaft position. Refer to
Electronic Ignition
System
for additional information.
Electronic Ignition
The electronic ignition system controls fuel combustion
by providing a spark to ignite the compressed air/fuel
mixture at the correct time. To provide optimum engine
performance, fuel economy, and control of exhaust
emissions, the PCM controls the spark advance of the
ignition system. Electronic ignition has the following
advantages over a mechanical distributor system:
No moving parts.
Less maintenance.
Remote mounting capability.
No mechanical load on the engine.
More coil cooldown time between firing events.
Elimination of mechanical timing adjustments.
Increased available ignition coil saturation time.
0013
Ignition Coils
A separate coil-at-plug module is located at each spark
plug. The coil-at-plug module is attached to the engine
with two screws. It is installed directly to the spark plug by
an electrical contact inside a rubber boot. A three-way
connector provides 12-volt primary supply from the
15-amp ignition fuse, a ground-switching trigger line from
the PCM, and a ground.
0001
Ignition Control
The ignition control (IC) spark timing is the PCM’s method
of controlling the spark advance and the ignition dwell.
The IC spark advance and the ignition dwell are
calculated by the PCM using the following inputs:
Engine speed.

6E–350
ENGINE DRIVEABILITY AND EMISSIONS
to the intake manifold through an orifice with a PCM
controlled pintle. During operation, the PCM controls
pintle position by monitoring the pintle position feedback
signal. The feedback signal can be monitored with Tech 2
as “Actual EGR Pos.” “Actual EGR Pos.” should always
be near the commanded EGR position (”Desired EGR
Pos.”). If a problem with the EGR system will not allow the
PCM to control the pintle position properly, DTC P1406
will set. The PCM also tests for EGR flow. If incorrect flow
is detected, DTC P0401 will set. If DTCs P0401 and/or
P1406 are set, refer to the DTC charts.
The linear EGR valve is usually activated under the
following conditions:
Warm engine operation.
Above-idle speed.
Too much EGR flow at idle, cruise or cold operation may
cause any of the following conditions to occur:
Engine stalls after a cold start.
Engine stalls at idle after deceleration.
Vehicle surges during cruise.
Rough idle.
Too little or no EGR flow may allow combustion
temperatures to get too high. This could cause:
Spark knock (detonation).
Engine overheating.
Emission test failure.
DTC P0401 (EGR flow test).
Poor fuel economy.
0017
EGR Pintle Position Sensor
The PCM monitors the EGR valve pintle position input to
endure that the valve responds properly to commands
from the PCM and to detect a fault if the pintle position
sensor and control circuits are open or shorted. If the
PCM detects a pintle position signal voltage outside the
normal range of the pintle position sensor, or a signal
voltage that is not within a tolerance considered
acceptable for proper EGR system operation, the PCM
will set DTC P1406.
General Description (Positive
Crankcase Ventilation (PCV) System)
Crankcase Ventilation System Purpose
The crankcase ventilation system is use to consume
crankcase vapors in the combustion process instead of
venting them to the atmosphere. Fresh air from the
throttle body is supplied to the crankcase and mixed with
blow-by gases. This mixture is then passed through the
positive crankcase ventilation (PCV) valve into the
common chamber.
Crankcase Ventilation System Operation
The primary control is through the positive crankcase
v e n t i l a t i o n ( P C V ) v a l v e . T h e PCV valve meters the flow at
a rate that depends on the intake vacuum. The PCV valve
restricts the flow when the inlet vacuum is highest. In
addition, the PCV valve can seal the common chamber
off in case of sudden high pressure in the crankcase.
028RV002
While the engine is running, exhaust fuses and small
amounts of the fuel/air mixture escape past the piston

ENGINE MECHANICAL 6A – 3
SERVICE INFORMATION
MAIN DATA AND SPECIFICATION
Engine type Diesel, four cycle water cooled inline
Camshaft type DOHC
Number of cylinders 4
Bore x stroke (mm) 95.4 x 104.9
Total piston displacement (cc) 2999
Compression ratio (to 1) 19.0
For Europe : 18.5
Engine weight (dry) N (kg/lb) 2492 (254/560) (A/T)
For Europe : 2422 (247/545) (A/T)
2649 (270/593) (M/T)
For Europe : 2697 (275/606) (M/T)
Engine idling speed (Reference) RPM 720
Compression pressure kpa (kg/cm
2/psi)-rpm 3040 (31/441)-200
Firing order 1–3–4–2
VALVE SYSTEM
Intake valves open at: B.T.D.C. 3°
close at: A.B.D.C. 57.6°
Exhaust valves open at: B.B.D.C. 56.5°
close at: A.T.D.C. 5°
Valve clearance (at cold) mm (in)
intake: 0.15 (0.006)
exhaust: 0.25 (0.01)
Oil filter Full flow and bypass combined type
Oil capacity (Original factory fill or rebuilt engine) 9.0 liters (7.9 US quarts)
Oil capacity (Service change)
with filter change 6.0 liters (6.3 US quarts)
without filter change 5.0 liters (5.3 US quarts)
Oil cooler Water cooled type
Inter cooler Air cooled type
Turbocharger method
Control method Wastegate control
Lubrication Pressurized control
Cooling method Coolant cooled
Crankshaft
As tufftriding (Nitrizing treatment) is applied to increase
crankshaft strength, crankpins and journals should not
be reground.
Piston Cooling
An oiling jet device for piston cooling is provided in the
lubricating oil circuit from the cylinder block oil gallery
via a check valve.
Take care not to damage any oiling jet when removing
and installing piston and connecting assembly.
Fuel Injection System
The injection system is oil rail type.
Quick On Start 4 System
QOS4 preheating system which features a quick-on
glow plug with thermometer control of the glowing time
and the afterglow time function, is applied.

ENGINE MECHANICAL 6A – 35
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and disconnect water hose
from thermostat hosing.
2. Remove intercooler assembly
Refer to “Intercooler” in this manual.
3. Remove bracket bolt of oil level gauge guide tube.
4. Remove PCV Hose.
5. Remove hoses from EGR, EGR vacuum sensor
and inlet/outlet of heater.
6. Disconnect harness connector form MAP sensor,
EGR vacuum sensor, ETC sensor, water
temperature unit, IAT sensor and EVRV.
7. Remove high pressure oil pipe.
8. Remove the two way valve.
9. Remove fuel pipe from between intake manifold
and high pressure oil pump.
10. Remove fixing bolts and nuts on the intake
manifold, then remove the intake manifold
assembly.
INSTALLATION
1. Install the intake manifold, tighten bolts and nuts to
the specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for bolt and nut
2. Install the fuel pipe and tighten to the specified
torque.To r q u e :
M16 bolt (apply engine oil) 4 Nꞏm (0.4 kgꞏm/2.9
lb ft)
Cap nut (M10) 13Nꞏm (1.3 kgꞏm/9.4 lb ft)
Fuel pipe (M10 apply engine oil) 14 Nꞏm (1.4
kgꞏm/10 lb ft)
3. Install two way valve.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
4. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler. If assembled without filling the oil rail
with oil, the time for starting the engine will be
longer.
5. Install the high pressure oil pipe immediately and
tighten the sleeve nut to the specified torque.
Torque : 80 Nꞏm (8 kgꞏm/57.9 lb ft)
6. Reconnect harness connector to MAP sensor, EGR
vacuum sensor, ETC sensor, Water temperature
unit, IAT sensor and EVRV.
7. Connect the hoses to EGR valve, EGR vacuum
sensor, and water inlet/outlet pipe for heater.
8. Connect PCV hose.
9. Install the oil level gauge guide tube and tighten
bracket bolt.
10. Install the intercooler assembly.
Refer to “Intercooler” in this manual.
11. Connect the hose to the thermostat housing and fill
with engine coolant.
For Europe
2
1
3
3 1 42
025R200005
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket

ENGINE FUEL 6C – 1
ENGINE FUEL
CONTENTS
GENERAL DESCRIPTION
General Description . . . . . . . . . . . . . . . . . . 6C–1
On-Vehicle Service . . . . . . . . . . . . . . . . . . 6C–7
Fuel Filter Assembly . . . . . . . . . . . . . . . . 6C–7
Fuel Filter Cartridge . . . . . . . . . . . . . . . . 6C–7
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–9
Fuel Pump Pipe . . . . . . . . . . . . . . . . . . . 6C–13High Pressure Oil Pump . . . . . . . . . . . . . 6C–15
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . 6C–20
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . 6C–21
Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . 6C–21
To realize the compatibility between low exhaust
emission and high engine output, an HEUI
(Hydraulically actuated Electronically controlled Unit
Injector) system, has been introduced. This system is
comprised of a hydraulic system, fuel system, and
electronic control system, using a high-pressure oil
pump in place of the conventional fuel injection pump.
The oil pressurized by means of this pump and by
signals from the ECM (Electronic Control Module)
actuates the fuel injector provided for each cylinder.
Inside of the fuel injector, fuel pressure is increased due
to the high-pressure oil. The ECM detects the driving
state of the vehicle, forms, signals sent by engine and
other part sensors, which determines the optimum fuel
injection amount and timing, thus controlling the fuel
injectors. Thus high engine output, good fuel economy,
and low exhaust emission are realized.When working on the fuel system, there are several
things to keep in mind:
1) Any time the fuel system is being worked on,
disconnect the negative battery cable except for
those tests where battery voltage is required.
2) Always keep a dry chemical (Class B) fire
extinguisher near the work area.
3) Replace all pipes with the same pipe and fittings
that were removed.
Clean and inspect “O” rings. Replace where
required.
4) Always relieve the line pressure before servicing
any fuel system components.
5) Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
6) After maintenance work, push priming pump and
send enough fuel to the fuel system before starting
the engine.
NOTE: In comparison with the conventional engine,
the capacity of fuel passage in the 4JX1 engine is
larger. It takes the priming pump more time to fill the
engine with fuel.

6C – 2 ENGINE FUEL
FUEL FLOW
1
14 Except above region
89
10111
2
2
4
12
5 6
7
3
13
14 For Europe, Nicaragua,
Argentina, Philippin
11
4
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Supply Pipe
(5) Fuel Filter with Priming Pump
(6) Fuel Pump
(7) High Pressure Oil Pump(8) Cylinder Head
(9) Injector
(10) Orifice
(11) Fuel Return Pipe
(12) Fuel Tank Pressure Release Hose
(13) Intake Air Duct
(14) Fuel Tank Pressure Control Valve
040R200001

ENGINE FUEL 6C – 7
ON-VEHICLE SERVICE
FUEL FILTER ASSEMBLY
REMOVAL
1. Disconnect battery ground cable.
2. Fuel Filler cap
3. Fuel Hose
1) Disconnect fuel hose from filter body.
Plug the hose ends to prevent fuel spillage.
4. Remove the Bolt on Fuel Filter Bracket
5. Remove Fuel Filter Assembly
INSTALLATION
1. Install the fuel filter assembly
2. Tighten the Fuel Filter Bracket Fixing Bolt
3. Fuel Hose
1) Connect hoses to filter body.
4. Fuel Filler Cap
1) Connect the battery ground cable.
2) Feed fuel to the fuel pump by priming, and bleed
the air from fuel system.
FUEL FILTER CARTRIDGE
DISASSEMBLY
1. Drain fuel completely from the fuel filter.
2. Protect the filter body with cloth and lightly grip with
a vise.
3. Remove the cartridge using a filter wrench.
Filter wrench: 5-8840-0203-0
1
Legend
(1) Priming Pump
012RW111
012RW112

6C – 8 ENGINE FUEL
REASSEMBLY
1. Clean the cartridge mounting surface of the filter
body so that the cartridge can be secured.
Apply engine oil thinly to new cartridge O-ring.
2. To facilitate bleeding, fill the new cartridge with light
oil.
3. Tighten the cartridge until O-ring comes in contact
with the seal, taking care not to spill the light oil.
4. Retighten 1/3 – 2/3 using a filter wrench.
Filter wrench: 5-8840-0203-0
Bleeding
1. Loosen air bleeding plug.
2. Operate priming pump to bleed the air in the fuel
line.
3. Operate the priming pump until the fuel is overflow
from air bleeding plug.
4. Tighten the air bleeding plug.
5. Start the engine, and if it is not started in 10
seconds or less, repeat the bleeding steps.
6. Make sure of no fuel leakage, and tighten the
priming pump.
Legend
(1) Priming Pump
NOTE: In comparison with the conventional engine,
the capacity of fuel passage in the 4JX1 engine is
larger. It takes the priming pump more time to fill the
engine with fuel.
012RW078
1
012RW111