1998 OPEL FRONTERA drain bolt

6J – 6 INDUCTION
Legend
(1) Pressure gauge
(2) Waste gate control rod
4) Check for cracks or breaks on the hose, if a
problem is found, the hose must be replaced.
CAUTION: Do not apply more than 120 Kpa (900
mmHg / 18.7 PSi) to waste gate actuator.
INSTALLATION
1. Install turbocharger assembly to exhaust manifold,
tighten to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm / 19.5 lb ft)2. Install exhaust valve assembly to outlet of
turbocharger, tighten bolts to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm / 19.5 lb ft)
3. Install heat protector.
4. Water inlet pipe.
1) Tighten water inlet pipe with new gasket.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
5. Oil drain pipe.
1) Tighten oil drain pipe with new gasket.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
6. Oil inlet pipe.
1) Apply about 100 cc engine oil to turbocharger
housing before installing the oil pipe.
2) Turn the turbine shaft by hand to lubricate the
bearing.
3) Install the oil inlet pipe with a new gasket, tighten
bolt to the specified torque.
Torque: 22 Nꞏm (2.2 kgꞏm / 15.9 lb ft) For M10
Torque: 54 Nꞏm (5.5 kgꞏm / 39.8 lb ft) For M14
2
1
036RW011
036RW005
036RW006

6J – 10 INDUCTION
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and remove water hose from
thermostat housing
2. Remove intercooler assembly.
3. Remove bracket fixing bolt of oil level gauge guide
tube.
4. Remove PCV hose.
5. Remove hoses from EGR valve, EGR vacuum
sensor and outlet of heater unit.
6. Disconnect harness connector from MAP sensor,
EGR vacuum sensor, ETC sensor, Water
temperature unit, IAT sensor and EVRV.
7. Remove high pressure oil pipe.
8. Remove two way check valve.
9. Remove fuel pipe.
10. Remove fixing bolts and nuts of intake manifold,
remove intake manifold assembly.
Legend
(1) Intake manifold
(2) Fixing portion of throttle valve
(3) EGR passage
(4) EGR valve
2
3
4
1
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket
025RW022
3124
025RW031

7A–22
AUTOMATIC TRANSMISSION (4L30–E)
Chart 16: Possible Causes Of
Transmission Fluid Leaks
Before attempting to correct an oil leak, the actual source
of the leak must be determined. In many cases, the
source of the leak may be difficult to determine due to
“wind flow” around the engine and transmission.
The suspected area should be wiped clean before in-
specting for the source of the leak.Oil leaks around the engine and transmission are gener-
ally carried toward the rear of the vehicle by the air
stream. In determining the source of an leak, the following
two checks should be made:
1. With the engine running, check for external line
pressure leaks.
2. With the engine off, check for oil leaks due to the
raised oil level caused by drainback of converter oil
into the transmission.
Possible Causes Of Fluid Leaks Due To Sealing Malfunction
240RX008
Legend
(1) Electrical Connector (Main Case) Seal
(2) Transmission Vent (Breather)
(3) Speed Sensor O–Ring
(4) Extension (Adapter) Lip Seal
(5) Extension (Adapter) to Main Case Gasket
(6) Overfill and Oil Drain Screws Gasket
(7) Oil Pan Gasket (Main Case)
(8) Selector Shaft Seal(9) Oil Cooler Connectors (2)
(10) Oil Pan Gasket (Adapter Case)
(11) Converter housing attaching bolts not correctly
torqued
(12) Converter Housing Lip Seal
(13) Line Pressure Tap Plug
(14) Electrical Connector (Adapter Case) Seal
(15) Adapter Case Seal Rings (2)

7A–39 AUTOMATIC TRANSMISSION (4L30–E)
Solenoid (Main Case Valve Body)
Removal
1. Raise the vehicle and support it on jack stands.
2. Disconnect battery ground cable.
3. Remove transfer and exhaust protectors.
4. Drain fluid.
5. Remove exhaust pipe and disconnect oxygen sensor
connector.
6. Support transfer case with a jack and remove third
crossmember.
7. Remove sixteen 10 mm screws, main case oil pan,
magnet, and gasket.
8. Remove three 13 mm screws, oil filter.
9. Disconnect wiring harness from band control
solenoid and shift solenoids. Pull only on connectors,
not on wiring harness.
10. Remove spring pin for shift solenoid A, shift solenoid
B, and band control solenoid respectively, using
suitable pliers taking care not to damage solenoids.
210RW010
244RW003
11. Remove shift solenoid A, shift solenoid B, band
control solenoid, and gaskets from main case valve
body. Do not pull on wiring harness. Remove
solenoids by grasping the metal tip.
Installation
1. Install shift solenoid A, shift solenoid B, band control
solenoid with new gaskets to main case valve body
respectively.
2. Carefully install spring pin with hammer to avoid
damage to valve body, etc.
243RW004
3. Connect wiring harness to solenoids.
4. Install oil filter with a new gasket and the three 13 mm
screws. Tighten the screws to the specified torque.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
5. Install magnet, main case oil pan with new gasket,
sixteen 10 mm screws. Tighten the screws to the
specified torque.
To r q u e : 11 N
m (1.1 kgꞏm/96 lb in)
6. Install third crossmember and rear mount nuts.
Tighten the nuts and bolts to the specified torque.
Third crossmember bolt: 76 N
m
(7.8 kgꞏm/56 lb ft)
Rear mount nut: 50 N
m (5.1 kgꞏm/37 lb ft)
7. Install exhaust pipe and connect oxygen sensor
connector. Tighten the bolts to the specified torque.
Exhaust pipe flange bolt torque:
43 N
m(4.4kgꞏm/32lbft)
8. Install the transfer and exhaust protectors. Tighten
the bolts to the specified torque.
Torque: 37 N
m (3.8 kgꞏm/27 lb ft)
9. Fill transmission through the overfill screw hole of oil
pan, using ATF DEXRON
–III. Refer to Changing
Transmission Fluid in this section.
10. Connect the battery ground cable.

7A–40
AUTOMATIC TRANSMISSION (4L30–E)
Solenoid (Adapter Case Valve Body)
Removal
1. Raise the vehicle and support it on jack stands.
2. Disconnect battery ground cable.
3. Drain fluid.
4. Remove transfer and exhaust protectors.
5. Remove exhaust pipe and disconnect oxygen sesnor
connector.
6. Remove adapter case oil pan twelve fixing 10 mm
screws, adapter case oil pan, and gasket.
NOTE: Oil pan still contains transmission fluid. Place a
large drain container under the oil pan and drain the fluid
carefully.
7. Disconnect wiring harness from force motor solenoid
and converter clutch solenoid. Pull only on
connectors, not on wiring harness.
8. Remove 11 mm bolt and converter clutch solenoid
with two O–rings.
210RW011
9. Remove 11 mm bolt, retainer, and force motor
solenoid.
210RW009
Installation
1. Install force motor solenoid, retainer, and 11 mm bolt
to adapter case valve body. Tighten the bolt to the
specified torque.
To r q u e : 1 0 N
m (1.0 kgꞏm/87 lb in)
2. Install converter clutch solenoid with two O– rings,
and 11 mm bolt to adapter case valve body. Tighten
the bolt to the specified torque.
Torque : 10 N
m (1.0 kgꞏm/87 lb in)
3. Connect wiring harness assembly to solenoids.
4. Install adapter case oil pan, new gasket, and twelve
10 mm screws. Tighten the screws to the specified
torque.
Torque : 11 N
m (1.1 kgꞏm/96 lb in)
5. Install exhaust pipe and connect oxygen sensor
connector. Tighten the bolt to the specified torque.
Exhaust pipe flange bolt torque :
43 N
m(4.4kgꞏm/32lbft)
6. Install transfer and exhaust protectors. Tighten the
bolt to the specified torque.
Torque : 37 N
m(3.8kgꞏm/27lbft)
7. Fill transmission through overfill screw hole oil pan,
using ATF DEXRON
–III. Refer to Changing
Transmission Fluid in this section.
8. Connect battery ground cable.

7A–41 AUTOMATIC TRANSMISSION (4L30–E)
Valve Body Assembly (Main Case)
Removal
1. Raise the vehicle and support it on jack stands.
2. Disconnect battery ground cable.
3. Remove transfer and exhaust protectors.
4. Drain fluid.
5. Remove exhaust pipe and disconnect oxygen sensor
connector.
6. Support transfer case with a jack and remove third
crossmember.
7. Remove sixteen 10 mm screws, main case oil pan,
magnet and gasket.
8. Remove three 13 mm oil filter fixing screws, then
remove oil filter.
9. Remove two 13 mm manual detent fixing screws,
then remove roller and spring assembly.
10. Disconnect wiring harness from band control
solenoid and shift solenoids. Pull only on connectors,
not on wiring harness.
11. Remove four 13 mm servo cover fixing screws, then
remove servo cover and gasket.
12. Remove seven 13 mm valve body fixing screws.
Disconnect the ground wire from the main case
valve body.
13. Remove main case valve body with manual valve link
and transfer plate. Note the position of the link (long
end into valve, short end into range selector lever).
14. Remove transfer plate gasket from main case.
15. Remove two check balls from main case.
Installation
1. Install two check balls to main case.
244RW002
2. Inspect electrical 4 pin connector and seal of main
case. Replace if necessary.3. Use two 5–8840–0022–0 (J–25025–B) guide pin to
install main case.
Install valve body assembly and manual valve link.
NOTE: Valve must be extended as the short end of
manual valve link is connected to the range selector lever.
Long end of link goes into valve.
4. Install seven 13 mm screws, and tighten them to the
specified torque.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
243RS008
5. Install 8.5 mm connector of ground wire the head of
this valve body bolt and reinstall it. Tighten the bolt to
the specified torque.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
244RW001
6. Remove two guide pins from main case.
7. Install servo cover gasket, cover, and four 13 mm
screws. Tighten the screws to the specified torque.
To r q u e : 2 5 N
m (2.6 kgꞏm/18 lb ft)

7A–43 AUTOMATIC TRANSMISSION (4L30–E)
Valve Body Assembly (Adapter Case)
Removal
1. Raise the vehicle and support it on jack stands.
2. Disconnect battery ground cable.
3. Drain fluid.
4. Remove transfer and exhaust protectors.
5. Remove exhaust pipe and disconnect oxygen sensor
connector.
6. Remove twelve 10 mm adapter case oil pan fixing
screws, adapter case oil pan, and gasket.
NOTE: Oil pan still contains transmission fluid. Place a
large drain container under the oil pan.
Drain the fluid carefully.
7. Disconnect wiring harness from force motor solenoid
and converter clutch solenoid. Pull only on
connectors, not on wiring harness.
8. Remove seven 13 mm screws from adapter case
valve body assembly, then remove transfer plate, two
gaskets, and adapter case valve body.
Installation
1. Inspect electrical 5 pin connector and seal of adapter
case. Replace if necessary.2. Install gasket, transfer plate, and gasket.
3. Install adapter case valve body and seven 13 mm
screws. Tighten the screws to the specified torque.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
4. Connect wiring harness assembly to converter clutch
solenoid and force motor.
5. Install oil pan gasket, oil pan, and twelve 10 mm
screws. Tighten the screws to the specified torque.
To r q u e : 11 N
m (1.1 kgꞏm/96 lb in)
6. Install exhaust pipe and connect oxygen sensor
connector. Tighten the bolts to the specified torque.
Exhaust pipe flange bolt torque:
43 N
m(4.4kgꞏm/32lbft)
7. Install transfer and exhaust protectors. Tighten the
bolts to the specified torque.
To r q u e : 3 7 N
m(3.8kgꞏm/27lbft)
8. Fill transmission through the overfill screw hole of oil
pan, using ATF DEXRON
–III. Refer to Changing
Transmission Fluid in this section.
9. Connect battery ground cable.
Powertrain Control Module (PCM)
Removal
1. Disconnect battery ground cable.
2. Remove front console.
3. Disconnect PCM wiring harness connectors from
PCM.
4. Remove three PCM retaining screws.
5. Remove two brackets from PCM.
826RV006
Installation
1. Install two brackets to PCM.
2. Install three PCM retaining screws.
3. Connect PCM wiring harness connectors to PCM.
4. Install front console.
5. Connect battery ground cable.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–83
826RY00005
826RY00006
249RY00011
249RY00012
TRANSMISSION CONTROL MODULE
(TCM)
REMOVAL
Preparation:
Disconnect negative (–) battery cable.
1. Disconnect the TCM harness connectors.
2. Remove fixing nuts (3 pieces) and TCM from the bracket.
INSTALLATION
To install, follow the removal steps in reverse order.
SHIFT SOLENOID AND LOCK-UP
SOLENOID
REMOVAL
Preparation:
• Disconnect negative (–) battery cable.
• Remove the rear sound cover.
• Drain the fluid.
Refer to
"ATF REPLACEMENT" in this section.
1. Remove the nineteen bolts and oil pan.
2. Remove the oil strainer assembly.
3. Disconnect the solenoid wiring connectors from the shift
solenoid S1(1), S2(2) and lock-up solenoid (3).
4. Remove each retaining bolts and solenoids.
INSTALLATION
To install, follow the removal steps in reverse order noting the
following point;
Tprque Nꞏm (kgꞏcm/lbꞏin)
Solenoid S1, S2 bolt 7 (70/61)
Lock-up solenoid bolt 10 (100/87)