1998 OPEL FRONTERA jump cable

6D1–4
ENGINE ELECTRICAL
4. Attach one end of the remaining cable to the negative
terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the air conditioning
compressor bracket or the generator mounting
bracket) of the vehicle with the discharged battery.
The ground connection must be at least 450 mm (18
in.) from the battery of the vehicle whose battery is
being charged.
WARNING: NEVER ATTACH THE END OF THE
JUMPER CABLE DIRECTLY TO THE NEGATIVE
TERMINAL OF THE DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical accessories
have been turned “OFF”.
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above
directions in reverse order.
Be sure to first disconnect the negative cable from the
vehicle with the discharged battery.
Battery Removal
061RS002
1. Remove negative cable (1).
2. Remove positive cable (2).
3. Remove retainer screw and rods (3).
4. Remove retainer (4).
5. Remove battery (5).
Battery Installation
1. Install battery (5).
2. Install retainer (4).
3. Instal retainer screw and rods (3).
NOTE: Make sure that the rod is hooked on the body
side.
4. Install positive cable (2).
5. Install negative cable (1).

6D3–13 STARTING AND CHARGING SYSTEM
Measure inner diameter of bushing in the rear cover, and
replace if it exceeds the limit.
Standard: 12.50 mm to 12.527 mm (0.492 in to
0.4932 in)
Limit: 12.60 mm (0.4961 in)
065RS028Measure inner diameter of bushing in the center bracket
(P), and replace if it exceeds the limit.
Standard: 18.01 mm to 18.127 mm (0.7091 in to
0.7137 in)
Limit: 18.15 mm (0.7146 in)
065RS029
Reassembly
To install, follow the removal steps in the reverse order,
noting the following points:
Grease application places
Bushing in rear cover and center bracket
Gears in reduction gear
Shift lever operating portion
Sliding portion of pinion
Plunger sliding portion of magnetic switch
Reassembling Yoke Assembly
Before reassembly, make sure that no metallic parts
attach to the yoke assembly. Because of strong magnetic
force, hold the yoke assembly and insert it slowly into the
armature.
To r q u e
Torque for each part (See Torque Specifications in
this section)
Pinion Jump–out Dimension
Connect the “+” cable of battery to terminal S and the “–”
cable to terminal M. Turn the switch on, and measure
pinion travel dimension in thrust direction from the
jump–out position.
In measuring the dimension, pull the pinion out a little in
the arrow direction.
Dimension(L): 0.05 mm to 1.5 mm (0.002 in to
0.06 in)
065RS030

6E–299 ENGINE DRIVEABILITY AND EMISSIONS
damage, therefore, it is important to use care when
handling and testing electronic components.
NOTE: To prevent possible Electrostatic Discharge
damage, follow these guidelines:
Do not touch the control module connector pins or
soldered components on the control module circuit
board.
Do not open the replacement part package until the
part is ready to be installed.
Before removing the part from the package, ground
the package to a known good ground on the vehicle.
If the part has been handled while sliding across the
seat, or while sitting down from a standing position, or
while walking a distance, touch a known good ground
before installing the part.
NOTE: To prevent internal PCM damage, the ignition
must be in the “OFF” position in order to disconnect or
reconnect power to the PCM (for example: battery cable,
PCM pigtail, PCM fuse, jumper cables, etc.).
IMPORTANT:When replacing the production PCM
with a service PCM, it is important to transfer the
broadcast code and production PCM number to the
service PCM label. This will allow positive identification of
PCM parts throughout the service life of the vehicle. Do
not record this information on the metal PCM cover.
IMPORTANT:The ignition should always be in the
“OFF” position in order to install or remove the PCM
connectors.
Service of the PCM should normally consist of either re-
placement of the PCM or EEPROM programming. If the
diagnostic procedures call for the PCM to be replaced,
the PCM should be checked first to ensure it is the correct
part. If it is, remove the faulty PCM and install the new
service PCM.
The service PCM EEPROM will not be programmed.
DTC P0601 indicates the check sum error.
Removal Procedure
1. Disconnect the negative battery cable.
2. Block the wheels.
3. Remove the front console assembly.
1. Remove the four screws.
TS23755
2. Remove the transfer shift lever knob by
unscrewing the knob.
3. Move the transmission gear selector out of the
park position.
4. Lift up sharply on the back edge of the assembly.
5. Disconnect the seat heater switch connectors (if
equipped).
6. Disconnect the POWER and WINTER switch
connectors.
7. Lift out the front console assembly.
TS23756

6E–330
ENGINE DRIVEABILITY AND EMISSIONS
Wiring and Connectors
Wiring Harness Service
The control module harness electrically connects the
control module 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.
PCM Connectors and Terminals
Removal Procedure
1. Remove the connector terminal retainer.
2. Push the wire connected to the affected terminal
through the connector face so that the terminal is
exposed.
3. Service the terminal as necessary.
Installation Procedure
1. Bend the tab on the connector to allow the terminal to
be pulled into position within the connector.
2. Pull carefully on the wire to install the connector
terminal retainer.
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
3. Untwist the conductors.
4. Strip the insulation as necessary.
048

ENGINE ELECTRICAL 6D – 3
ON-VEHICLE SERVICE
BATTERY CHARGING
Observe the following safety precautions when
charging the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during the
charging procedure.
Battery charging should be discontinued or the rate
of charge reduced if the battery feels hot to the
touch.
Battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas or
spew electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue
dot or ring, it may be necessary to jiggle or tilt the
battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be
either quick-charged or slow-charged in the same
manner as other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
JUMP STARTING
JUMP STARTING WITH AN AUXILIARY
(BOOSTER) BATTERY
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: Failure to carefully follow the jump
starting procedure could result in the following:
1. Serious personal injury, particularly to your
eyes.
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one or
both vehicles.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode. Remove any rings, watches, or other jewelry
before working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with your
eyes or skin.
Never allow battery fluid to come in contact with fabrics
or painted surfaces.
Battery fluid is a highly corrosive acid.Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface, immediately and
thoroughly rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of the reach of young
children.
JUMP STARTING PROCEDURE
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector lever in the “PARK”
position.
If the vehicle is equipped with a manual
transmission place the shift lever in the “NEUTRAL”
position.
Turn “OFF” the ignition.
Turn “OFF” all lights and any other accessory
requiring electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the
positive terminal of the discharged battery.
Do not allow the vehicles to touch each other.
This will cause a ground connection, effectively
neutralizing the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the
negative terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the A/C compressor
bracket or the generator mounting bracket) of the
vehicle with the discharged battery.
This ground connection must be at least 450 mm
(18 in) from the battery of the vehicle whose battery
is being charged.
WARNING: Never attach the end of the jumper
cable directly to the negative terminal of the dead
battery.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical
accessories have been turned “OFF”.
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above
directions in the reverse order.
Be sure to first disconnect the negative cable from
the vehicle with the discharged battery.

ENGINE ELECTRICAL 6D – 13
Pinion
1) Check by hand to see if the pinion rotates smoothly
in the dirve direction, or if it is locked when it is
rotated reversely.
If not, replace the pinion.
Yoke assembly
1) Check the magnet inside the yoke.
Replace the yoke assembly if it is broken.
REASSEMBLY
To install, follow the removal steps in the reverse order,
noting the following points:
Grease application places
1) Gears in reduction gear
2) Shift lever operating portion
3) Sliding potion of pinion
4) Plunger sliding portion of magnetic switch
Pinion jump-out dimension
1) Connect the (+) cable of battery to terminal S and
the (–) cable to terminal M. Turn the switch on, and
measure pinion travel dimension “L” in thrust
direction from the jump-out position.
In measuring the dimension, pull the pinion out a little in
the arrow direction.
Dimension L: 0.3 – 1.5 mm (0.01 – 0.06 in)If the measured value is out of standard, adjust the of
shims.
Legend
(1) Shim
065RW048
S
+
L M
065RW054
1
065RW053

6E–207 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
damage, therefore, it is important to use care when
handling and testing electronic components.
NOTE: To prevent possible Electrostatic Discharge
damage, follow these guidelines:
Do not touch the control module connector pins or
soldered components on the control module circuit
board.
Do not open the replacement part package until the
part is ready to be installed.
Before removing the part from the package, ground
the package to a known good ground on the vehicle.
If the part has been handled while sliding across the
seat, or while sitting down from a standing position, or
while walking a distance, touch a known good ground
before installing the part.
NOTE: To prevent internal ECM damage, the ignition
must be in the “OFF” position in order to disconnect or
reconnect power to the ECM (for example: battery cable,
ECM pigtail, ECM fuse, jumper cables, etc.).
IMPORTANT:When replacing the production ECM
with a service ECM, it is important to transfer the
broadcast code and production ECM number to the
service ECM label. This will allow positive identification of
ECM parts throughout the service life of the vehicle. Do
not record this information on the metal ECM cover.
IMPORTANT:The ignition should always be in the
“OFF” position in order to install or remove the ECM
connectors.
Service of the ECM should normally consist of either re-
placement of the ECM. If the diagnostic procedures call
for the ECM to be replaced, the ECM should be checked
first to ensure it is the correct part. If it is, remove the
faulty ECM and install the new service ECM.
DTC P0601 indicates the check sum error.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the ECM connector.
035RW093
3. Remove the bolts ECM bracket and battery bracket.
035RW094
4. Remove the ECM.
035RW092

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