engine OPEL FRONTERA 1998 Workshop Manual

6E–304
ENGINE DRIVEABILITY AND EMISSIONS
2. Install the air filter element in the air cleaner housing.
TS23794
3. Install the air cleaner lid on the MAF sensor and the air
cleaner housing.
TS23973
4. Tighten the clamp and secure the four latches
between the lid and the air cleaner housing.
Idle Air Control (IAC) Valve
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the IAC electrical connector.
3. Remove the bolts and the IAC valve from the throttle
body.
NOTE: Do not clean the IAC valve by soaking it in
solvent. The valve will be damaged as a result.
TS23745
Cleaning, Inspection, and
Measurement Procedure
Clean the IAC valve O-ring sealing surface, pintle
valve seat and air passage.
– Use carburetor cleaner and a parts cleaning brush to
remove carbon deposits. Do not use a cleaner that
contains methyl ethyl ketone. This is an extremely
strong solvent and not necessary for this type of
deposit.
– Shiny spots on the pintle are normal and do not
indicate misalignment or a bent pintle shaft.
– If the air passage has heavy deposits, remove the
throttle body for complete cleaning.
TS23746
Inspect the IAC valve O-ring for cuts, cracks, or
distortion. Replace the O-ring if damaged.

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.
101RW005
3. Remove the accelerator control cable (on the throttle
valve end).
101RW006

6E–306
ENGINE DRIVEABILITY AND EMISSIONS
4. Remove the accelerator control cable (on the
accelerator pedal end).
TS23982
5. Remove the grommet.
6. Remove the accelerator control cable.
TS23983
Inspection Procedure
Check the following items, and replace the control cable if
any abnormality is found:
The control cable should move smoothly.
The control cable should not be bent or kinked.
The control cable should be free of damage and
corrosion.
Installation Procedure
1. Install the accelerator control cable.
TS23983
2. Install the grommet.
3. Install the accelerator control cable (on the
accelerator pedal end).
TS23982

6E–307 ENGINE DRIVEABILITY AND EMISSIONS
4. Install the accelerator control cable (on the throttle
valve end).
101RW006
5. Install the adjusting nut.
101RW007
6. Adjust the accelerator cable at the throttle body.
Refer to
Accelerator Cable Adjustment.
7. Install the engine cover.
Adjustment Procedure
1. Loosen the adjusting nut and lock nut.
2. Pull outer cable closing fully the throttle valve.
3. Tighten adjusting nut and lock nut temporarily.
035RW004
4. Loosen adjusting nut by three turns and tighten lock
nut. Then, manually operating the throttle valve,
make sure that the valve lever returns up to the
stopper screw.
IMPORTANT:The valve lever must return up to the
stopper screw. If the valve lever does not reach the
stopper screw, repeat the procedure again from step 1.
5. It does not reach the stopper screw, repeat from step
1.
TS23782

6E–308
ENGINE DRIVEABILITY AND EMISSIONS
Accelerator Pedal Replacement
Removal Procedure
1. Disconnect the cruise control cable from the
accelerator pedal assembly.
TS24053
2. Disconnect the accelerator pedal control cable from
the accelerator pedal assembly.
TS24054
3. Disconnect the wiring harness from the kick-down
switch.
TS24038
4. Remove the two screws from the accelerator pedal
assembly.
TS24055
5. Remove the accelerator pedal assembly from the
bulkhead.

6E–309 ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Install the accelerator pedal assembly on the
bulkhead.
2. Install the two screws to the accelerator pedal
assembly.
TS24055
3. Connect the wiring harness to the kick-down switch.
TS24038
4. Connect the accelerator pedal control cable to the
accelerator pedal assembly.
TS24054
5. Connect the cruise control cable to the accelerator
pedal assembly.
TS24053

6E–310
ENGINE DRIVEABILITY AND EMISSIONS
Pedal Stroke Adjustment Procedure
1. Loosen the jam nut and rotate the kick-down switch
counterclockwise.
TS24039
2. Fully depress the pedal and hold it by hand. Rotate
the switch clockwise until the switch clicks.
3. Rotate the switch 1/2 turn further and lock it in this
position by tightening the jam nut.
TS24040
4. Step on the accelerator pedal and make sure there is
a clicking sound at the full-stroke position.
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.
TS23767
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 Procedure
1. Disconnect the negative battery cable.
2. Remove the fuel filler cap.
041RW005

6E–311 ENGINE DRIVEABILITY AND EMISSIONS
3. Disconnect the fuel line from the fuel filter on the
engine side.
4. Disconnect the fuel line from the fuel filter on the fuel
tank side.
041RW006
5. Remove the bolt on the fuel filter holder.
041RW007
6. Remove the fuel filter.
041RW008
Inspection Procedure
1. Replace the fuel filter when the following occur:
Fuel leaks from the fuel filter body.
The fuel filter body is damaged.
The fuel filter is clogged with dirt or sediment.
2. If the drain hole is clogged, clean the drain.
041RW009

6E–312
ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Install the fuel filter in the correct direction.
041RW008
2. Install the bolt on the fuel filter holder.
041RW007
3. Connect the fuel line on the engine side.
4. Connect the fuel line on the fuel tank side.
041RW006
5. Install the fuel filler cap.
041RW005
6. Connect the negative battery cable.

6E–313 ENGINE DRIVEABILITY AND EMISSIONS
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.).
TS22907
4. Disconnect the wiring connector from the fuel gauge
unit.
TS23771
5. Remove the fuel gauge unit retaining screws.
6. Remove the fuel gauge unit.
Cover or plug the fuel tank to prevent dust, dirt, or
debris from entering the tank.
TS22911
Installation Procedure
1. Install the fuel gauge unit.
2. Install the fuel gauge unit retaining screws.
TS22911