1998 OPEL FRONTERA Electrical

6E–323 ENGINE DRIVEABILITY AND EMISSIONS
11. Connect the fuel filler fuse at the tank.
12. Connect the air breather hose at the tank.
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13. Fill the fuel tank with fuel.
14. Tighten the fuel filler cap.
15. Connect the negative battery cable.
Throttle Body (TB)
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the cooling system. Refer to
Cooling System.
3. Remove the accelerator cable assembly. Refer to
Accelerator Cable in Engine Speed Control System..
4. Disconnect the electrical connectors:
Throttle position (TP) sensor.
Idle air control (IAC) solenoid.
Intake air temperature (IAT) sensor. Refer to
Intake Air Temperature Sensor.
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5. Disconnect the vacuum hose below the air horn.
6. Remove the intake air duct clamp.
7. Disconnect the intake air duct.
8. Disconnect the coolant lines from the throttle body.
9. Remove the bolts from the common chamber.
10. Remove the throttle body from the common chamber.
11. Remove the gasket from the upper intake manifold.
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12. Remove the IAC. Refer to Idle Air Control (IAC)
Solenoid
.
13. Remove the TP sensor. Refer to
Throttle Position
(TP) Sensor
.
Inspection Procedure
NOTE: Do not use solvent of any type when you clean the
gasket surfaces on the intake manifold and the throttle
body assembly. The gasket surfaces and the throttle
body assembly may be damaged as a result.
If the throttle body gasket needs to be replaced,
remove any gasket material that may be stuck to the
mating surfaces of the manifold.
Do not leave any scratches in the aluminum casting.
Installation Procedure
1. Install the TP sensor. Refer to Throttle Position (TP)
Sensor
.
2. Install the IAC. Refer to
Idle Air Control (IAC)
Solenoid
.
3. Install the gasket on the common chamber.
4. Install the throttle body on the common chamber.

6E–324
ENGINE DRIVEABILITY AND EMISSIONS
5. Secure the gasket and the throttle body with the four
bolts.
The vacuum lines must be properly routed under
the throttle body before tightening the mounting
bolts.
Tighten
Tighten the throttle body mounting bolts to 24 Nꞏm
(17 lb ft.).
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6. Install the coolant lines.
7. Connect all the vacuum lines.
8. Install the intake air duct.
9. Tighten the intake air duct clamp.
10. Connect all the electrical connectors:
Throttle position (TP) sensor.
Idle air control (IAC) solenoid.
Intake air temperature (IAT) sensor. Refer to
Intake Air Temperature Sensor.
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11. Install the accelerator cable assembly. Refer to
Accelerator Cable in Engine Speed Control System..
12. Fill the cooling system. Refer to
Cooling System.
13. Install the negative battery cable.
Electronic Ignition System
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector at the ignition coil.
3. Remove the two screws that secure the ignition coil to
the rocker cover.
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4. Remove the ignition coil and the spark plug boot from
the spark plug.
Twist the ignition coil while pulling it straight up.
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5. Use the spark plug socket in order to remove the
spark plug from the engine.

6E–325 ENGINE DRIVEABILITY AND EMISSIONS
Spark Plug Gap Check
Check the gap of all spark plugs before installation.
Use a round wire feeler gauge to ensure an accurate
check.
Plugs installed with the wrong gap can cause poor
engine performance and excessive emissions.
Installation Procedure
NOTE: The plug must thread smoothly into the cylinder
head and be fully seated. Use a thread chaser if
necessary to clean the threads in the cylinder head.
Cross-threading or failure to fully seat the spark plug can
cause plug overheating, exhaust blow-by gas, or thread
damage. Do not overtighten the spark plugs. Over
tightening can cause aluminum threads to strip.
1. Install the spark plug in the engine. Use the
appropriate spark plug socket.
Tighten
Tighten the spark plug to 18 Nꞏm (13 lb ft.).
2. Install the ignition coil and spark plug boot over the
spark plug.
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3. Secure the ignition coil to the rocker cover with two
screws.
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4. Connect the electrical connector at the ignition coil.
5. Connect the negative battery cable.
Catalytic Converter
Removal and Installation Procedure
Refer to Engine Exhaust in Engine.
Air Conditioning Relay
Removal Procedure
1. Remove the fuse and relay box cover from under the
hood.
2. Consult the diagram on the cover to determine which
is the correct relay.
3. Insert a small screwdriver into the catch slot on the
forward side of the fuel pump relay.
The screwdriver blade will release the catch inside.
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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.

6E–328
ENGINE DRIVEABILITY AND EMISSIONS
3. Connect the vacuum hoses to the EVAP canister
purge solenoid.
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4. Connect the electrical connector to the EVAP canister
purge solenoid.
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Fuel Tank Vent Valve
Removal and Installation Procedure
Refer to Fuel Pump
Linear Exhaust Gas
Recirculation (EGR) Valve
Removal Procedure
1. Disconnect the negative battery cable.2. Disconnect the electrical connector at the EGR valve.
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3. Remove the bolt and the nut from the upper intake
manifold.
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4. Remove the EGR valve from the upper intake
manifold.
5. Remove the gasket from the upper intake manifold.
Installation Procedure
1. Install the gasket on the upper intake manifold.
2. Install the EGR valve on the upper intake manifold.
3. Secure the EGR valve and the gasket with the bolt
and the nut.

6E–329 ENGINE DRIVEABILITY AND EMISSIONS
NOTE: It is possible to install the EGR valve rotated 180
from the correct position. Make sure that the base of the
valve is placed so that it aligns with the mounting flange.
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4. Connect the electrical connector at the EGR valve.
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5. Connect the negative battery cable.
Positive Crankcase Ventilation
(PCV) Valve
Removal Procedure
1. Remove the vacuum hose at the PCV valve.
Slide the clamp back to release the hose.2. Pull the PCV valve from the rubber grommet in the
right valve cover.
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Inspection Procedure
1. Shake the valve and listen for the rattle of the needle
inside the valve.
2. If the valve does not rattle, replace the valve.
Installation Procedure
1. Push the PCV valve into the rubber grommet in the
left valve cover.
2. Install the vacuum hose on the PCV valve and secure
the vacuum hose with the clamp.
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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.
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3. Untwist the conductors.
4. Strip the insulation as necessary.
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6E–332
ENGINE DRIVEABILITY AND EMISSIONS
2. Cover the splice with tape in order to insulate it from
the other wires.
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3. Twist the wires as they were before starting this
procedure.
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4. Tape the wires with electrical tape. Hold in place.
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Weather-Pack Connector
Tools Required
J 28742-A Weather-Pack II Terminal Remover
Removal Procedure
A Weather-Pack connector can be identified by a rubber
seal at the rear of the connector. This engine room
connector protects against moisture and dirt, which could
from oxidation and deposits on the terminals. This
protection is important, because of the low voltage and
the low amperage found in the electronic systems.
1. Open the secondary lock hinge on the connector.
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