Opel Frontera UE. Manual - part 854

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X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION

6. Remove two bolts holding EGR valve.
7. Remove EGR valve and gasket from the manifold.

057RX001

Inspection Procedure

1. Inspect the air passage for a restrtiction. If there is

restriction, remove the object. Do not use any type of
solvent, it may damage electrical system of EGR
valve.

2. Inspect restriction for valve movement. If there is

restriction remove the object.

014RX056

Installation Procedure

1. Place the gasket and EGR valve on to the intake

manifold.

2. Install mounting bolts and tighten.
3. Connect electrical connector at EGR valve
4. Connect the crankshaft breather hose and secure it

with clamps.

5. Install the air intake duct. Refer to Air Intake Duct

Installation Procedure. 

6. Connect the negative battery cable.

014RX057

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 for
all wire harness repair procedures.

ECM 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 pulledinto position within the connector.

2. Pull carefully on the wire to install the connector

terminal retainer.

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X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION

Connectors And Terminals

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.

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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Installation Procedure

1. Splice the wires using splice clips and rosin core

solder.

2. Wrap each splice to insulate.
3. Wrap the splice with mylar and with the drain

(uninsulated) wire.

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X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION

4. Tape over the whole bundle to secure.

050

Twisted Leads

Removal Procedure

1. Locate the damaged wire.
2. Remove the insulation as required.

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Installation Procedure

1. Use splice clips and rosin core solder in order to splice

the two wires together.

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2. Cover the splice with tape in order to insulate it from

the other wires.

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X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION

3. Twist the wires as they were before starting this

procedure.

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4. Tape the wires with electrical tape.

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Weather–Pack Connector

Tools Required

5-8840-0388-0 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
form 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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2. Use tool 5-8840-0388-0 or the equivalent to remove

the pin and the sleeve terminals. Push on
5-8840-0388-0 to release.

NOTE: Do not use an ordinary pick or the terminal may
be bent or deformed. Unlike standard blade terminals,
these terminals cannot be straightened after they have
been improperly bent.

071