1998 OPEL FRONTERA service

6E–227 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
QOS
Diagnostics
– Malfunction Indicator Lamp (Service Engine
Soon lamp)
– Data Link Connector (DLC)
– Data Output
ECM Service Precautions
The ECM is designed to withstand normal current draws
associated with vehicle operation. Avoid overloading any
circuit. When testing for opens and shorts, do not ground
or apply voltage to any of the ECM’s circuits unless
instructed to do so. These circuits should only be tested
using digital voltmeter. The ECM should remain
connected to the ECM or to a recommended breakout
box.
Intake Throttle Position (ITP) Sensor
ITP sensor is a potentiometer type and installed to the
intake throttle valve body. A voltage of 5V is applied
constantly from ECM to ITP sensor thereby to determine
by change in voltage the opening of the intake throttle
valve during warming up.
Transmission Range Switch
IMPORTANT:The vehicle should not be driven with the
transmission range switch disconnected; idle quality will
be affected.
The four inputs from the transmission range switch
indicate to the ECM which position is selected by the
transmission selector lever.
For more information on the transmission on the
transmission range switch, refer to
Automatic
Tr a n s m i s s i o n
.
Accelerator Position Sensor (AP)
AP sensor is a potentiometer type and installed to
accelerator pedal bracket. A voltage of 5V constantly
applied from ECM to the sensor thereby to determine the
accelerator pedaling angle by change in voltage. Further,
this sensor is provided with an accelerator switch, which
is set off only when the accelerator pedal is stepped on.
Aftermarket Electrical and Vacuum
Equipment
Aftermarket (add-on) electrical and vacuum equipment is
defined as any equipment which connects to the vehicle’s
electrical or vacuum systems that is installed on a vehicle
after it leaves the factory. No allowances have been
made in the vehicle design for this type of equipment.
NOTE: No add-on vacuum equipment should be added
to this vehicle.
NOTE: Add-on electrical equipment must only be
connected to the vehicle’s electrical system at the battery
(power and ground).
Add-on electrical equipment, even when installed to
these guidelines, may still cause the powertrain system to
malfunction. This may also include equipment not
connected to the vehicle electrical system such asportable telephones and radios. Therefore, the first step
in diagnosing any powertrain problem is to eliminate all
aftermarket electrical equipment from the vehicle. After
this is done, if the problem still exists, it may be diagnosed
in the normal manner.
Electrostatic Discharge Damage
Electronic components used in the ECM are often
designed to carry very low voltage. Electronic
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static
electricity can cause damage to some electronic
components. By comparison, it takes as much as 4000
volts for a person to feel even the zap of a static
discharge.
TS23793
There are several ways for a person to become statically
charged. The most common methods of charging are by
friction and induction.
An example of charging by friction is a person sliding
across a vehicle seat.
Charge by induction occurs when a person with well
insulated shoes stands near a highly charged object
and momentary touches ground. Charges of the
same polarity are drained off leaving the person
highly charged with the opposite polarity. Static
charges can cause damage, therefore it is important
to use care when handling and testing electronic
components.
NOTE: To prevent possible electrostatic discharge
damage, follow these guidelines:
Do not touch the ECM connector pins or soldered
components on the ECM circuit board.
Do not open the replacement part package until the
part is ready to be installed.
Before removing the part from the package, ground
the package to a known good ground on the vehicle.
If the part has been handled while sliding across the
seat, while sitting down from a standing position, or
while walking a distance, touch a known good ground
before installing the part.

ENGINE EXHAUST 6F – 1
ENGINE EXHAUST
CONTENTS
CAUTION: Exhaust system components must have
enough clearance from the underbody to prevent
overheating of the floor pan and possible damage to the passenger compartment, insulation and trim
materials.
General Description . . . . . . . . . . . . . . . . . . 6F–2
Hangers . . . . . . . . . . . . . . . . . . . . . . . . . 6F–2
Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 6F–3
Front Exhaust Pipe . . . . . . . . . . . . . . . . . 6F–3Center Exhaust Pipe . . . . . . . . . . . . . . . . 6F–5
Exhaust Silencer . . . . . . . . . . . . . . . . . . . 6F–6
Rear Exhaust Pipe . . . . . . . . . . . . . . . . . 6F–7

ENGINE EXHAUST 6F – 3
ON-VEHICLE SERVICE
FRONT EXHAUST PIPE
Rattles and noise vibrations in the exhaust system are
usually caused by misalignment of parts. When aligning
the system, leave all bolts or nuts loose until all parts
are properly aligned; then tighten, working from front to
rear.
1. Check connections for looseness or damage,
especially for exhaust gas leakage.
2. Check clamps and rubbers for weakness, cracks or
damage.3. If any part of the converter heat shield is damaged
or dented to the extent that it contacts the catalyst,
repair or replace.
4. Check for dents or damage and for any holes or
cracks caused by corrosion.
3
2 1
Legend
(1) Front exhaust pipe
(2) Center exhaust pipe
(3) Mounting rubber
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6J – 6 INDUCTION
INSPECTION AND REPAIR
Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is
discovered during inspection.
Minor servicing operations are described in this section.
Contact the nearest IHI SERVICE FACILITY for major
repairs and maintenance.
Refer to IHI SERVICE NETWORK at the end of this
section for the location of your area’s IHI SERVICE
FA CI L I T Y.
Turbine shaft end play.
1) Set a dial indicator to the turbine shaft end.
2) Apply a force of 11.8 N (1.2 kg / 2.6 lb)
alternately to the compressor wheel and and the
turbine wheel end.
3) Read the dial indicator.
Turbine End Play
Standard: 0.03 – 0.06 mm (0.0012 – 0.0024 in)
Limit: 0.09 mm (0.0035 in)Turbine shaft and bearing clearance
1) Set a dial indicator to the turbine shaft center
through the center housing oil drain port.
2) Move the turbine shaft from side to side.
3 Read the dial indicator.
Turbine Shaft and Bearing Clearance
Standard: 0.056 - 0.127 mm (0.0022 - 0.0050 in)
Limit: 0.14 mm (0.0055 in)
Waste gate operation
1) Remove hose from waste gate actuator side and
install pressure gauge (1) to the waste gate
actuator.
2) Operate pump of pressure gauge while engine is
stopped.
3) Read pressure at the control rod (2) move 2mm.
Pressure: 106 – 115 kPa
(796 – 862 mmHg/ 15.4 – 16.7 PSi)
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INDUCTION 6J – 13
IHI SERVICE NETWORK
For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger Service
Facility.
HEADQUARTERS
ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD. (IHI)
General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN
TEL: 81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430
CHINA
IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, People’s R epublic of CHINA
TEL: 86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX: 210343 IHIPK CN
TA I WA N
IHI TAIPEI OFFICE
Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL: 886-(2)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
TLX: 11320 IHICO
THAILAND
IHI BANGKOK OFFICE
8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND
TEL: 66-(2)-236-3490, 7356, 9099
FAX: 66-(2)-236-7340
TLX: 82375 IHICO TH
MALAYSIA
IHI KUALA LUMPUR OFFICE
Letter Box No. 52, 22nd Floor, UBN Tower,
10 Jin. P. Ramlee 50250 Kuala Lumpur, MALAYSIA
TEL: 60-(3)-232-1255, 1271
FAX: 60-(3)-232-1418
TLX: IHI KLMA 20257
INDONESIA
IHI JAKARTA OFFICE
9th Floor, Skyline Building JI. M.H. Thamrin, No. 9, Jakarta, INDONESIA
TEL: 62-(21)-32-2147, 390-2211
FAX: 62-(21)-32-3273
TLX: 44175 IHIJKT

7A–1 AUTOMATIC TRANSMISSION (4L30–E)
TRANSMISSION
AUTOMATIC TRANSMISSION (4L30–E)
CONTENTS
Service Precaution 7A–3. . . . . . . . . . . . . . . . . . . . . .
Construction 7A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Range Reference Chart 7A–4. . . . . . . . . . . . . . . . . .
Normal Operation Of 1998 4L30–E
Transmission 7A–5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 7A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Information 7A–5. . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis Procedure 7A–8. . . . . . . . . . . . .
Preliminary Inspection Chart 7A–9. . . . . . . . . . . . . .
Checking Transmission Fluid Level and
Condition 7A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Driving 7A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical / Hydraulic Diagnosis Check Trans
Indicator Chart 7A–12. . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical / Hydraulic Diagnosis Symptoms
Index 7A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stall Test 7A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Test 7A–23. . . . . . . . . . . . . . . . . . . . . .
Shift Speed Chart 7A–24. . . . . . . . . . . . . . . . . . . . . . .
Lockup Speed Chart 7A–26. . . . . . . . . . . . . . . . . . . . .
Changing Transmission Fluid 7A–27. . . . . . . . . . . . .
Selector Lever 7A–27. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 7A–27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Switch 7A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (With Transfer Case) 7A–31. . . . . . . .
Transmission And Associated Parts 7A–31. . . . . .
Removal 7A–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid (Main Case Valve Body) 7A–36. . . . . . . . .
Removal 7A–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–36. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid (Adapter Case Valve Body) 7A–37. . . . . . .
Removal 7A–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–37. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Main Case) 7A–38. . . . . . . .
Removal 7A–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–38. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Adapter Case) 7A–40. . . . . .
Removal 7A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) 7A–40. . . . . . . . . Removal 7A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Sensor (Extension Housing) 7A–41. . . . . . . .
Removal 7A–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Temperature Sensor
(Adapter Case) 7A–41. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–42. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Oil Seal (Converter Housing) 7A–42. . . . . . . .
Removal 7A–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–42. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal (Extension Housing) 7A–43. . . . . . . . .
Removal 7A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (4L30–E) 7A–43. . . . . . . . . . . . . . . . . .
Disassembly 7A–43. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 7A–47. . . . . . . . . . . . . . . . . . . . . . . . . .
Converter Housing And Oil Pump Assembly 7A–57
Disassembled View 7A–57. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–57. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–57. . . . . . . . . . . . . . . . . .
Reassembly 7A–57. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 7A–58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7A–58. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–58. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–58. . . . . . . . . . . . . . . . . .
Reassembly 7A–58. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Case Valve Body 7A–59. . . . . . . . . . . . . . . . . . .
Disassembled View 7A–59. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–59. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–60. . . . . . . . . . . . . . . . . .
Reassembly 7A–60. . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter Case Valve Body 7A–61. . . . . . . . . . . . . . . .
Disassembled View 7A–61. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–61. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–61. . . . . . . . . . . . . . . . . .
Reassembly 7A–61. . . . . . . . . . . . . . . . . . . . . . . . . .
Third Clutch And Sprag Unit 7A–63. . . . . . . . . . . . . .
Disassembled View 7A–63. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–63. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–64. . . . . . . . . . . . . . . . . .
Reassembly 7A–64. . . . . . . . . . . . . . . . . . . . . . . . . .
Third Clutch 7A–65. . . . . . . . . . . . . . . . . . . . . . . . . . . .

7A–3 AUTOMATIC TRANSMISSION (4L30–E)
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
Construction
A07RS001
Legend
(1) Torque Converter Clutch (TCC)
(2) Fourth Clutch (C4)
(3) Overrun Clutch (OC)
(4) Overdrive Unit
(5) Reverse Clutch (RC)
(6) Second Clutch (C2)(7) Third Clutch (C3)
(8) Ravigneaux Planetary Gear Set
(9) Brake Band (B)
(10) Overdrive Free Wheel (One Way Clutch)
(OFW)
(11) Sprag Free Wheel (One Way Clutch) (PFW)

7A–27 AUTOMATIC TRANSMISSION (4L30–E)
Changing Transmission Fluid
There is no need to change the transmission fluid unless
the transmission is used under one or more of the
following heavy duty conditions.
A. Repeated short trips
B. Driving on rough roads
C. Driving on dusty roads
D. Towing a trailer
If the vehicle is used under these conditions, change the
fluid every 20,000 miles (32,000 km.)
More over, the remaining life percentage of ATF can be
estimated by using Tech 2 as an auxiliary tool to judge the
right time for ATF replacement.
The remaining life percentage is calculated from ATF’S
heat history. When it is close to 0%, ATF replacement is
recommended.
1. Place a large drain pan under the oil pan.
2. Remove the transmission oil drain screw (2) and drain
fluid.
3. Tighten drain screw (2).
Torque: 38 N
m (3.9 kgꞏm/28 lb ft)
4. Remove the transmission overfill screw (1) and fill
transmission through overfill screw opening, using
DEXRON
–III ATF.
NOTE: Add transmission fluid until it flows out over the
overfill screw opening.
5. Let engine idle until a fluid temperature between 32
C
(90
F) and 57C (135F) is reached.6. Add transmission fluid until it flows out over the overfill
screw opening, then close the overfill screw (1).
To r q u e : 3 8 N
m (3.9 kgꞏm/28 lb ft)
NOTE: To prevent fluid leaks, the overfill screw and oil
drain screws gasket must be replaced each time these
screws are removed.
NOTE: Check transmission fluid temperature with
service scan tool.
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Selector Lever
Inspection
1. Make sure that when the shifter control lever is shifted
from “P” to “L”, a “clicking” can be felt at each shift
position. Make sure that the gear corresponds to that
of the position plate indicator.
2. Check to see if the shifter lever can be shifted as
shown in illustration.
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