1998 OPEL FRONTERA rack

6E–305 ENGINE DRIVEABILITY AND EMISSIONS
In order to install a new IAC valve, measure the
distance between the tip of the pintle and the
mounting flange. If that measurement is 28 mm (1.1
in.) or less, the valve needs no adjustment. If the
measurement is greater than 28 mm (1.1 in.), apply
finger pressure and retract the valve. The force
required to retract the pintle on a new valve will not
damage the valve, shaft, or pintle.
NOTE: Do not push or pull on the IAC valve pintle on IAC
valves that have been in service. The force required to
move the pintle may damage it.
IMPORTANT:Use an identical replacement part in
order to replace a valve. IAC valve pintle shape and
diameter are designed for the specific application.
TS23746
Installation Procedure
1. Install the IAC valve on the throttle body with the bolts.
Tighten
Tighten the bolts to 1 Nꞏm (9 lb in.).
TS23745
2. Connect the IAC valve electrical connector.
3. Install the negative battery cable.
Common Chamber
Removal and Installation Procedure
Refer to Common Chamber in Engine Mechanical.
Accelerator Cable Assembly
Removal Procedure
1. Remove the engine cover.
2. Loosen the adjusting nut on the cable bracket
mounting on the common chamber.
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3. Remove the accelerator control cable (on the throttle
valve end).
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6E–314
ENGINE DRIVEABILITY AND EMISSIONS
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 Procedure
NOTE: If the fuel injectors are leaking, the engine oil may
be contaminated with fuel. Check the oil for signs of
contamination and change the oil and the filter if
necessary.
NOTE: Use care in removing the fuel injectors in order to
prevent damage to the fuel injector electrical connector
pins or the fuel injector nozzles. The fuel injector is an
electrical component and should not be immersed in any
type of cleaner as this may damage the fuel injector.
IMPORTANT:Fuel injectors are serviced as a complete
assembly only.
1. Disconnect the negative battery cable.
2. Remove the upper intake manifold. Refer to
Common Chamber in Engine Mechanical..
3. Remove the fuel rail. Refer to
Fuel Rail.
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4. Remove the injector retainer clip.
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5. Remove the fuel injector assembly.
6. Remove the O-ring from the fuel injector.
7. Remove the O-ring backup from the fuel injector .
Inspection Procedure
1. Inspect the O-rings for cracks or leaks.
2. Replace worn or damaged O-rings.
3. Lubricate the new O-rings with engine oil before
installation.

6E–318
ENGINE DRIVEABILITY AND EMISSIONS
2. Remove the fuel pump relay from the underhood
relay box. Refer to
Fuel Pump Relay.
TS23976R
3. Start the engine and allow it to stall.
4. Crank the engine for 30 seconds.
5. Disconnect the negative battery cable.
Fuel Pump Assembly
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain all the fuel from the tank.
3. Install and tighten the drain plug.
Tighten
Tighten the drain plug to 20 Nꞏm (14 lb ft.).
4. Remove the fuel tank. Refer to
Fuel Tank.
5. Remove the retaining screws from the fuel tank.
6. Remove the fuel pump assembly from the fuel tank.
Cover the fuel pump opening in order to prevent
dust, dirt, or debris from entering the fuel tank.
TS23795
Inspection Procedure
1. Inspect the fuel pump gasket for tears, cracks,
stretching, or rotting. If any of these conditions are
found, replace the fuel pump gasket.
2. Inspect the in-tank fuel filter for tears or evidence of
dirt, debris, or water in the fuel. If any of these
conditions are found, replace the in-tank fuel filter.
Installation Procedure
1. Install the fuel pump assembly.
2. Install the fuel pump assembly retaining screws.
3. Install the fuel tank assembly. Refer to
Fuel Tank.
4. Fill the tank with fuel.
5. Tighten the fuel filler cap.
6. Connect the negative battery cable.
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6E–320
ENGINE DRIVEABILITY AND EMISSIONS
IMPORTANT:An eight-digit identification number is
stamped on the side of the fuel rail. Refer to this number
when you service the fuel rail or when a replacement part
is required.
TS24022
Before removal, the fuel rail assembly may be cleaned
with a spray type engine cleaner. Follow the spray
package instructions. Do not immerse the fuel rails in
liquid cleaning solvent.
1. Depressurize the fuel system. Refer to Fuel Pressure
Relief Procedure in this Section.
2. Disconnect the negative battery cable.
3. Remove the engine cover.
4. Disconnect the accelerator pedal cable from throttle
body and cable bracket.
5. Disconnect the connectors from manifold absolute
pressure sensor, solenoid valve, electric vacuum
sensing valve.
6. Disconnect the vacuum hose on canister VSV and
positive crankcase ventilation hose.
7. Remove the common chamber. Refer to the common
chamber in Engine Mechanical.
1. Lift up carefully on the fuel injectors. Do not
separate the fuel injectors from the fuel rail.
2. If an injector becomes separated from the fuel
rail, the infector O-ring seals and the retainer clip
must be replaced.
3. Drain residual fuel into an approved container.
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8. If removal of the fuel pressure regulator is necessary,
refer to
Fuel Pressure Regulator.
9. If removal of the fuel injectors is necessary, refer to
Fuel Injectors.
Installation Procedure
1. If the fuel injectors were removed, install them. Refer
to
Fuel Injectors.
2. If the fuel pressure regulator was removed, install it.
Refer to
Fuel Pressure Regulator.
3. Install the common chamber. Refer to common
chamber in engine Mechanical.
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6E–321 ENGINE DRIVEABILITY AND EMISSIONS
4. Connect the vacuum hose on Canister VSV and
positive crankcase ventilation hose.
5. Connect the connectors to manifold absolute
pressure sensor, solenoid valve, electric vacuum
sensing valve.
6. Connect the accelerator pedal cable to throttle body
and cable bracket.
7. Install the engine cover.
8. Connect the negative battery cable.
9. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel rail and in the injectors.
Fuel Tank
Removal Procedure
1. Disconnect the negative battery cable.
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank into an approved
container.
4. Install and tighten the drain plug.
Tighten
Tighten the drain plug to 20 Nꞏm (14 lb ft.).
5. Disconnect the fuel filler hose at the fuel tank.
6. Disconnect the air breather hose at the fuel tank.
TS23796
7. Remove the undercover retaining bolts.
8. Remove the undercover.
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9. Disconnect the wiring connector to the fuel pump.
10. Disconnect the wiring connector to the fuel gauge
unit.
11. Remove the fuel gauge unit connector from the
bracket.
12. Disconnect the EVAP vapor hose.
13. Disconnect the fuel supply hose.
14. Disconnect the fuel return hose.
Plug the hoses to prevent dust from entering the
hoses.
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6E–322
ENGINE DRIVEABILITY AND EMISSIONS
15. Remove the fuel tank retaining bolts on both sides.
16. Remove the fuel tank.
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Installation Procedure
1. Install the fuel tank.
Place the flanges on the left and right side of the
tank on the bracket.
2. Install the fuel tank retaining bolts.
Tighten
Tighten the fuel tank retaining bolts to 36 Nꞏm (27 lb
ft.).
TS23770
3. Connect the fuel return hose.
4. Connect the fuel supply hose.
5. Connect the EVAP vapor hose.
6. Connect the wiring connector for the fuel gauge unit.
7. Connect the fuel gauge wiring connector to the
bracket.
8. Connect the wiring connector for the fuel pump.
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9. Install the undercover.
10. Secure the undercover with the retaining bolts.
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6E–326
ENGINE DRIVEABILITY AND EMISSIONS
4. Pull the relay straight up and out of the fuse and relay
box.
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Installation Procedure
1. Insert the relay into the correct place in the fuse and
relay box with the catch slot facing forward.
2. Press down until the catch engages.
An audible “click” will be heard.
3. Install the fuse and relay box cover.
TS23986
EVAP Canister Hoses
Service Information
To view the routing of the EVAP canister hoses, refer to
Vehicle Emission Control Information in Diagnosis. Use
6148M or equivalent when you replace the EVAP canister
hoses.
EVAP Canister
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the three hoses from the EVAP canister.
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3. Remove the retaining two bolts on the mounting
bracket and slide the canister out of mounting
bracket.
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Inspection Procedure
1. Inspect the hoses for cracks and leaks.
2. Inspect the canister for a damaged case.

6E–327 ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Slide the canister into mounting bracket and install
the mounting bracket two bolts.
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2. Connect the three hoses to the EVAP canister.
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3. Disconnect the negative battery cable.
EVAP Canister Purge Solenoid
Removal Procedure
1. Disconnect the electrical connector from the EVAP
canister purge solenoid.2. Disconnect the vacuum hoses from the EVAP
canister purge solenoid.
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3. Remove the EVAP canister purge solenoid retaining
bolt from the upper intake manifold.
4. Remove the EVAP canister purge solenoid.
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Installation Procedure
1. Install the EVAP canister purge solenoid on the upper
intake manifold.
2. Install the EVAP canister purge solenoid retaining
bolt.