battery OPEL FRONTERA 1998 Workshop Manual

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.
TS23795

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.
014RW164
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.
TS23797
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.
TS23769

6E–323 ENGINE DRIVEABILITY AND EMISSIONS
11. Connect the fuel filler fuse at the tank.
12. Connect the air breather hose at the tank.
TS23796
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.
035RW023
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.
035RW024
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.).
035RW024
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.
035RW023
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.
014RW108
4. Remove the ignition coil and the spark plug boot from
the spark plug.
Twist the ignition coil while pulling it straight up.
014RW091
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.
014RW108
3. Secure the ignition coil to the rocker cover with two
screws.
014RW091
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.
T321092

6E–326
ENGINE DRIVEABILITY AND EMISSIONS
4. Pull the relay straight up and out of the fuse and relay
box.
TS23986
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.
014RW145
3. Remove the retaining two bolts on the mounting
bracket and slide the canister out of mounting
bracket.
014RW146
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.
014RW146
2. Connect the three hoses to the EVAP canister.
014RW145
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.
014RW136
3. Remove the EVAP canister purge solenoid retaining
bolt from the upper intake manifold.
4. Remove the EVAP canister purge solenoid.
014RW137
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.
014RW137
4. Connect the electrical connector to the EVAP canister
purge solenoid.
014RW138
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.
014RW139
3. Remove the bolt and the nut from the upper intake
manifold.
014RW098
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.
014RW098
4. Connect the electrical connector at the EGR valve.
014RW139
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.
014RW097
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.
014RW097