1998 OPEL FRONTERA Electrical

6E–203 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Engine Coolant Temperature
(ECT) Sensor
Removal Procedure
NOTE: Care must be taken when handling the engine
coolant temperature (ECT) sensor. Damage to the ECT
sensor will affect proper operation of the fuel injection
system.
1. Disconnect the negative battery cable.
2. Drain the radiator coolant. Refer to
Draining and
Refilling Cooling System
in Engine Cooling.
3. Disconnect the electrical connector.
4.Remove the ECT sensor from the front side of the
intake manifold.
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Installation Procedure
1. Apply sealer (LOCTITE 262) or the equivalent to the
threads of the ECT sensor.
2. Install the ECT sensor in the front side of the intake
manifold.
Tighten
Tighten the ECT sensor to 19 Nꞏm (14 lb ft.).
3. Connect the electrical connector.
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4. Fill the radiator with coolant. Refer to Draining and
Refilling Cooling System
in Engine Cooling.
5. Connect the negative battery cable.
Intake Air Temperature (IAT)
Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector from the IAT
sensor.
3. Remove the IAT sensor from the intake air duct by
using a rocking motion while pulling the sensor.
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6E–204
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Install the IAT sensor into the grommet in the intake
air duct.
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2. Correct the IAT electrical connector.
3. Connect the negative battery cable.
Manifold Absolute Pressure
(MAP) Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the EGR valve.
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3. Disconnect the MAP sensor connector from the MAP
sensor.
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4.Remove the bolts and the MAP sensor from the
intake manifold.
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6E–206
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
3. Disconnect the electrical connector from the OT
sensor.
4. Remove the OT sensor.
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Installation Procedure
1. Install the OT sensor.
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2. Connect the OT sensor electrical connector.
3. Install the battery.
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4. Connect the negative battery cable.
Malfunction Indicator Lamp
(MIL)
Removal and Installation Procedure
Refer to Meter in Electrical section.
Engine Control Module (ECM)
Service Precaution
NOTE: To prevent possible electrostatic discharge
damage to the ECM, do not touch the connector pins or
soldered components on the circuit board.
When replacing the ECM to prevent possible electro
damage, follow these guidelines:
Before removing the ECM, disconnect the negative
battery cable.
Before install the ECM, install the negative battery cable.
Electrostatic Discharge (ESD)
Damage
Electronic components used in the control systems are
often designed to carry very low voltage. Electronic
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static
electricity can cause damage to some electronic
components. By comparison, it takes as much as 4,000
volts for a person to even feel the zap of a static
discharge.
There are several ways for a person to become statically
charged. The most common methods of charging are by
friction and by induction. An example of charging by
friction is a person sliding across a car seat.
Charging by induction occurs when a person with well
insulated shoes stands near a highly charged object and
momentarily touches ground. Charges of the same
polarity are drained off leaving the person highly charged
with the opposite polarity. Static charges can cause

6E–209 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
2. Remove the cover of the intercooler.
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3. Remove the bolts and the left side bracket to the
intercooler.
4 . R e m o v e t h e a i r d u c t w i t h b r a c k e t f r o m t h e i n t e r c o o l e r.
5. Remove the throttle body from the intake manifold.
6. Disconnect the ITP sensor electrical connector and
throttle motor control connector.
7. Remove the bolts and the ITP sensor from the throttle
body.
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NOTE: Do not clean the ITP sensor by soaking it in
solvent. The sensor will be damaged as a result.
Function Check
Use a Tech 2 to check the ITP sensor output voltage at
closed throttle.
The voltage should be under 0.85 volt.
If the reading is greater than 0.85 volt, check the
throttle shaft to see if it is binding.
If the throttle shaft is not binding and the throttle cable
is properly adjusted, install a new ITP sensor.
Installation Procedure
1. Install the ITP sensor on the throttle body with the
bolts.
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2. Install the throttle body to the intake manifold and the
air duct with bracket between throttle body and
intercooler.
Torque: 20 Nꞏm (14 Ib ft)
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3. Connect the ITP sensor electrical connector and
throttle motor control connector.
4. Install the bracket to the intercooler.
5. Install the cover of intercooler.
6. Install the negative battery cable.

6E–210
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Vehicle Speed Sensor (VSS)
Removal Procedure
CAUTION: The VSS is located on the right side of
the transfer case just ahead of the rear propeller
shaft and very close to the exhaust pipes. Be sure
that the exhaust pipes are cool enough to touch
before trying to remove the VSS. If the pipes are hot,
you could be burned.
1. Disconnect the negative battery cable.
2. Disconnect the VSS electrical connector.
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3. Remove the bolt and the clamp securing the VSS in
place.
IMPORTANT:H a v e a c o n t a i n e r r e a d y t o c a t c h a n y f l u i d
that leaks out when the VSS is removed from the transfer
case.
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4. Remove the VSS from the transfer case by wiggling it
slightly and pulling it straight out.
Inspection Procedure
1. Inspect the electrical connector for signs of corrosion
or warping. Replace the VSS if the electrical
connector is corroded or warped.
2. Inspect the VSS driven gear for chips, breaks, or worn
condition. Replace the VSS if the driven gear is
chipped, broken or worn.
3. Inspect the O-ring for wear, nicks, tears, or
looseness. Replace the O-ring if necessary.
Installation Procedure
1. Install the VSS in the transfer case with the notch for
the connector facing the rear.
2. Secure the VSS in place with the clamp and the bolt.
Tighten
Tighten the bolt to 16 Nꞏm (12 lb ft.).
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3. Connect the VSS electrical connector.
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4. Check the transfer case oil level. Add fluid if
necessary.

6E–211 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
5. Connect the negative battery cable.
Air Cleaner/Air Filter
Removal Procedure
1. Loosen the clamp between the air cleaner lid and the
duct.
2. Release the four latches securing the lid to the air
cleaner housing.
3. Remove the air cleaner lid.
4. Remove the air filter element.
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5. Remove the retaining bolts and the air cleaner
housing from the vehicle.
Installation Procedure
1. Install the air cleaner housing in the vehicle with the
retaining bolts.
2. Install the air filter element in the air cleaner housing.
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3. Install the air cleaner lid on the air duct and the air
cleaner housing.
4. Tighten the clamp and secure the four latches
between the lid and the air cleaner housing.
Accel Position (AP) Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector to the AP sensor.
3.Remove the bolts and the accelerator pedal
assembly from the bulkhead.
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4. Remove the bolts and AP sensor from the accelerator
pedal assembly.
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6E–212
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Install the AP sensor to the accelerator pedal
assembly.
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2. Install the accelerator pedal assembly to the
bulkhead.
3. Connect the electrical connector to the AP sensor.
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4. Connect the negative battery cable.
Accelerator Pedal Replacement
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector to the AP sensor.3.Remove the bolts and the accelerator pedal
assembly from the bulkhead.
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4. Remove the bolts and AP sensor from the accelerator
pedal assembly.
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Installation Procedure
1. Install the AP sensor to the accelerator pedal
assembly.
2. Install the accelerator pedal assembly to the
bulkhead.

6E–213 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
3. Connect the electrical connector to the AP sensor.
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4. Connect the negative battery cable.
Fuel Filter Cap
General Description
The fuel filler cap includes a vacuum valve and a pressure
valve.
If high vacuum or high pressure occurs in the fuel tank,
each valve works to adjust the pressure in order to
prevent damage to the tank at the EGR valve.
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Inspection Procedure
NOTE: Replace the fuel filler cap with the same type of
filler cap that was originally installed on the vehicle.
Check the seal ring in the filler cap for any abnormality
and for seal condition.
Replace the filler cap if any abnormality is found.
Fuel Filter
Removal and Installation Procedure
Refer to the Engine fuel in the 4JX1 Engine section.
Fuel Gauge Unit
Removal Procedure
1. Disconnect the negative battery cable.
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank.
Tighten
Tighten the drain plug to 20 Nꞏm (14 lb ft.).
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4. Disconnect the wiring connector from the fuel gauge
unit.
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5. Remove the fuel gauge unit retaining screws.