OPEL FRONTERA 1998 Workshop Manual

6E–208
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Installation Procedure
1. Install the ECM.
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2. Install the bolts, ECM bracket and battery bracket.
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3. Connect the ECM connector.
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4. Connect the negative battery cable.
If the ECM is replaced, the new ECM will need to be
programmed.
EEPROM
General Description
The Electronically Erasable Programmable Read Only
Memory (EEPROM) is a permanent memory that is
physically soldered within the ECM. The EEPROM
contains program and calibration information that the
ECM needs to control powertrain operation.
Functional Check
1. Perform the On-Board Diagnostic System Check.
2. Start the engine and run for one minute.
3. Scan for DTCs using the Tech 2.
Intake Throttle Position (ITP)
Sensor
Removal Procedure
1. Disconnect the negative battery cable.

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.

6E–214
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
6. Remove the fuel gauge unit.
Cover or plug the fuel tank to prevent dust, dirt, or
debris from entering the tank.
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Installation Procedure
1. Install the fuel gauge unit.
2. Install the fuel gauge unit retaining screws.
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3. Connect the wiring connector to the fuel gauge unit.
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4. Fill the fuel tank with fuel.
Tighten the fuel filler cap.
Check for leaks at the fuel gauge unit gasket.
5. Connect the negative battery cable.
Fuel Injectors
Removal and Installation Procedure
Refer to Engine Fuel in 4JX1 Engine Section.
Fuel Temperature Sensor
Removal Procedure
CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when servicing
fuel lines or connections. Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before disconnecting the fittings. The
towels will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
1. Disconnect the negative battery cable.
2. Remove the intercooler assembly.
3. Remove the cylinder head. Refer to engine
mechanical section.

6E–215 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
4. Remove the rear side engine hanger.
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5. Remove the fuel return adapter.
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6. Remove the fuel pressure sensor from the fuel return
adapter.
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Installation Procedure
1. Install the fuel pressure sensor in the fuel return
adapter.
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6E–216
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
2. Install the fuel return adapter.
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3. Install the rear side engine hanger. Tighten the rear
side engine hanger fixing bolts to specified torque.
Torque: 19 Nꞏm (14 lb ft)
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4. Install the cylinder head. Refer to engine mechanical
section.
5. Install the intercooler assembly.
6. Connect the negative battery cable.
Rail Pressure (RP) Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the air cleaner cover and air duct.
3. Remove the intercooler assembly.
4. Remove the injector oil pipe.
5. Remove the intake throttle valve.
6. Remove the cylinder head cover noise inselation.
7. Remove the cylinder head cover.
8. Remove the RP sensor.
Installation Procedure
Refer to the RP Sensor Programming.
1. Install the RP sensor.
2. Install the cylinder head cover.
3. Install the cylinder head cover noise inselation.
4. Install the intake throttle valve.
5. Install the injector oil pipe.
6. Install the intercooler assembly and tighten
intercooler assembly fixing bolts to specified torque.
Torque: 20 Nꞏm (14 lb ft)
7. Install the air cleaner cover and air duct.
8. Connect the negative battery cable.
Fuel Tank
Removal Procedure
Refer toEngine Fuel in 4JX1 Engine section.
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6E–217 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Throttle Body (TB)
Removal Procedure
1. Disconnect the negative battery cable.
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.
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5. Remove the throttle body assembly from the intake
manifold.
6. Disconnect the ITP sensor electrical connector.
Installation 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.
1. Install the throttle body assembly 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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2. Connect the ITP sensor electrical connector and
throttle motor control connector.
3. Install the bracket to the intercooler.
4. Install the cover of intercooler.
5. Connect the negative battery cable.
Air Conditioning (A/C) 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. Pull the relay straight up and out of the fuse and relay
box.
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.
Exhaust Gas Recirculation
(EGR) Vacuum Switch Valve
(VSV)
Removal Procedure
1. Disconnect the negative battery cable.