1998 OPEL FRONTERA Workshop Manual

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Page 4881 of 6000

OPEL FRONTERA 1998 Workshop Manual 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 p

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”.

Page 4882 of 6000

OPEL FRONTERA 1998 Workshop Manual 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

Page 4883 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–226
ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck
D06RW106
Circuit Description
The powertrain control module (PCM) monitors the EGR
valve pintle position

6E–226
ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0404 EGR Open 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 pintle position is different from
commanded position. If the PCM detects a pintle position
signal indicates more than 15 points different between
current and commanded and more than 15 seconds, the
PCM will set DTC P0404.
Conditions for Setting the DTC
Ignition voltage is between 11 and 16 volts.
Intake Air temp is more than 3C.
Desire EGR position is more than 0.
The difference between desired EGR and current EGR
is less than 3%.
Difference EGR pintle position between current and
commanded position becomes more than 15% and
last more than 15 seconds, and this condition meets
three times in a trip. Then it trigger, the PCM lights on.
Action Taken When the DTC Sets
The PCM will illuminate the malfunction indicator lamp
(MIL) as soon as failure detected 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 P0404 can be cleared by using 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 may
cause EGR stuck open or unsmooth operation. Those
carbon deposit may occur by unusual port operation.
Clean up carbon may make smooth function of EGR
valve.
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.

Page 4884 of 6000

OPEL FRONTERA 1998 Workshop Manual 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
Syste

Page 4885 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–228
ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage
D06RW106
Circuit Description
The powertrain control module (PCM) monitors the EGR
valve pintle position

Page 4886 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–229 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0405 – EGR Low Volt
StepActionVa l u e ( s )Ye sNo
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2
Go to OBD
System
C

6E–229 ENGINE DRIVEABILITY AND EMISSIONS
DTC P0405 – EGR Low Volt
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 “DTC” info for DTC P0405
until the DTC P0405 test runs. Note the result.
Does Tech 2 indicates DTC P0405 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. Disconnect the EGR harness connector.
2. Ignition “ON”.
3. At the EGR valve, use a DVM to check the voltage
at the 5 volt reference wire (RED) and ground (B).
Did the DVM indicate the specified value?
4–6 VGo to Step 6Go to Step 7
61. Disconnect the EGR harness connector.
2. Measure resistance between terminal B and D.
Was resistance in range?
5–5.5 KGo to Step 10Go to Step 17
71. Ignition “ON”.
2. At the PCM connector, backprobe with a DVM at the
5 volt reference for the EGR valve.
Did the DVM indicate the specified value?
4–6 VGo to Step 8Go to Step 9
8Repair the open 5 volt reference circuit.
Is the action complete?
—Verify repair—
9Repair the damaged sensor ground wire.
Is the action complete?
—Verify repair—
101. Disconnect the EGR harness
2. Use an ohmmeter to measure between the pintle
position pin and the sensor ground pin on the EGR
valve.
NOTE: J-35616 Connector Test Adapter Kit may be
useful for gaining access to the recessed pins on the
valve.
Was the ohmmeter reading approximately equal to the
specified value?
1 to 1.25 KGo to Step 11Go to Step 17
111. Ignition “ON”.
2. Backprobe with a DVM to measure voltage at EGR
valve pintle position pin and sensor ground pin.
Was voltage in range?
Less than
0.1 V
Go to Step 17Go to Step 12

Page 4887 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–230
ENGINE DRIVEABILITY AND EMISSIONS
DTC P0405 – EGR Low Volt
StepNo Ye s Va l u e ( s ) Action
121. Ignition “ON”.
2. Backprobe with a DVM to measure voltage at PCM
sensor ground pin and

Page 4888 of 6000

OPEL FRONTERA 1998 Workshop Manual 6E–231 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage
D06RW106
Circuit Description
The powertrain control module (PCM) monitors the EGR
valve pintle positi

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