1998 OPEL FRONTERA oil pump

6G – 2 ENGINE LUBRICATION
GENERAL DESCRIPTION
LUBRICATION CHART
P
33
32
31
30
1
2
3
4
56
8
97
10
11
12
13
14 23 29
25
28
27262415
16
17 18
19 20 21 22
Legend
(1) Camshaft
(2) Balance Shaft
(3) Crankshaft
(4) Oil Cooler and Oil Filter Assembly
(5) Oil Filter Relief Valve 98 Kpa (1 kg/cm
2/14.2 Psi)
(6) Oil Cooler Relief Valve 245 Kpa (2.5 kg/cm2/
36 Psi)
(7) First Oil Pump
(8) Main Oil Relief Valve 588 Kpa (6 kg/cm
2/ 85 Psi)
(9) To Oil Pan
(10) To Oil Pan
(11) Injector
(12) Oil Rail(13) Sub Oil Filter Relief Valve 98 Kpa (1 kg/cm
2/
14.2 Psi)
(14) Sub Oil Filter
(15) Relief Valve 588 Kpa (6 kg/cm
2/ 85 Psi)
(16) Second Oil Pump
(17) Oil Pan
(18) To Oil Pan
(19) Balance Shaft
(20) Cooling Jet Relief Valve 245 Kpa (2.5 kg/cm
2/
36 Psi)
(21) Cooling Jet
(22) To Oil Pan
(23) Two Way Check Valve
(24) Nipple Filter
040RW018

ENGINE LUBRICATION 6G – 3
To meet a newly adopted electronically controlled fuel
injection system using engine oil two oil pumps have
been provided to increase circulating oil capacity.
The first oil pump serves mainly to lubricate the engine
parts, while the second mainly serves the fuel injectors
and partially cools the pistons.
The oil cooler is provided on the first oil pump side and
uses engine coolant.
OIL FLOW
Legend
(1) Oil Pump
(2) Regulator Valve
(3) Oil Cooler
(4) Oil Filter Relief Valve
(5) Full Flow Filter
(6) Oil Cooler Relief Valve
(7) Gallery
OIL PUMP SPECIFICATIONS
OIL FILTER SPECIFICATIONS
Legend
(1) Oil cooler assembly
(2) Oil filter assembly (25) Edge Filter
(26) Edge Filter
(27) High Pressure Oil Pump Assembly
(28) To Oil Pan
(29) Pressure Control Valve(30) To Oil Pan
(31) Turbocharger
(32) Oil Gallery
(33) Timing Gear Train
17 65 4
3
2
050RW010
1
2
050RW009

ENGINE LUBRICATION 6G – 5
OIL PUMP
REMOVAL
1. Remove battery ground cable.
2 Raise the vehicle and support with suitable safety
stand.
3. Drain engine oil.
4. Remove flywheel assembly.
5. Remove rear plate (For A/T) or flywheel housing
(For MT).
6. Remove first oil pump assembly from cylinder block
and second oil pump assembly from crank case.
INSPECTION AND REPAIR
1. Inspect flaws and/or wear on the teeth surface.
2. Inspect abnormal wear journal on the gear and in
the drive spline.
3. If problem is found during inspection, the worn parts
must be replaced.
INSTALLATION
1. Install first oil pump.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
2. Install second oil pump.
Torque: 20 Nꞏm (2ꞏ0 kg.m / 14.5 lb ft)
2
1
5
6
3
4
Legend
(1) Flywheel
(2) Rear Plate
(3) First Oil Pump(4) Second Oil Pump
(5) O-ring (For 1st oil pump)
(6) O-ring (For 2nd oil pump)
012RW097

INDUCTION 6J – 5
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
FACILITY.
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)
036RW008
036RW010
036RW009
036RW007

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 2000 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 (V6 3.2L 6VD1 Model) 7A–24. . .
Shift Speed Chart (V6 3.5L 6VE1 Model) 7A–26. .
Lockup Speed Chart (V6 3.2L 6VD1 Model) 7A–28
Lockup Speed Chart (V6 3.5L 6VE1 Model) 7A–28
Changing Transmission Fluid 7A–29. . . . . . . . . . . . .
Selector Lever 7A–29. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 7A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Switch 7A–31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (With Transfer Case) 7A–33. . . . . . . .
Transmission And Associated Parts 7A–33. . . . . .
Removal 7A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid (Main Case Valve Body) 7A–39. . . . . . . . .
Removal 7A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid (Adapter Case Valve Body) 7A–40. . . . . . .
Removal 7A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Main Case) 7A–41. . . . . . . .
Removal 7A–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Adapter Case) 7A–43. . . . . .
Removal 7A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 7A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) 7A–43. . . . . . . . .
Removal 7A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Sensor (Extension Housing) 7A–44. . . . . . . .
Removal 7A–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–44. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Temperature Sensor
(Adapter Case) 7A–44. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Oil Seal (Converter Housing) 7A–45. . . . . . . .
Removal 7A–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal (Extension Housing) 7A–46. . . . . . . . .
Removal 7A–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A–46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (4L30–E) 7A–46. . . . . . . . . . . . . . . . . .
Disassembly 7A–46. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 7A–50. . . . . . . . . . . . . . . . . . . . . . . . . .
Converter Housing And Oil Pump Assembly 7A–60
Disassembled View 7A–60. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–60. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–60. . . . . . . . . . . . . . . . . .
Reassembly 7A–60. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 7A–61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7A–61. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–61. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–61. . . . . . . . . . . . . . . . . .
Reassembly 7A–61. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Case Valve Body 7A–62. . . . . . . . . . . . . . . . . . .
Disassembled View 7A–62. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–62. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–63. . . . . . . . . . . . . . . . . .
Reassembly 7A–63. . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter Case Valve Body 7A–64. . . . . . . . . . . . . . . .
Disassembled View 7A–64. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–64. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–64. . . . . . . . . . . . . . . . . .
Reassembly 7A–64. . . . . . . . . . . . . . . . . . . . . . . . . .
Third Clutch And Sprag Unit 7A–65. . . . . . . . . . . . . .
Disassembled View 7A–65. . . . . . . . . . . . . . . . . . . .
Disassembly 7A–65. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A–66. . . . . . . . . . . . . . . . . .

7A–20
AUTOMATIC TRANSMISSION (4L30–E)
Chart 15a: Possible Causes of Low Line Pressure
StepActionYe sNo
1Check oil level.
Was the problem found?
Fill with ATFGo to Step 2
2Check for defective throttle position sensor.
Was the problem found?Replace throttle
position sensor
Go to Step 3
3Check for plugged, loose, or damaged oil filter (79).
Was the problem found?Inspect oil filter,
tighten bolts or
replace oil filter
(79)
Go to Step 4
4Check for a stuck force motor plunger (404). (Adapter case valve
body)
Was the problem found?Replace force
motor plunger
(404)
Go to Step 5
5Check for a stuck feed limit valve (412). (Adapter case valve body)
Was the problem found?Replace feed limit
valve (412)
Go to Step 6
6Check for loose converter bolts (4 & 5).
Was the problem found?Tighten converter
bolts (4 & 5)
Go to Step 7
7Check for a stuck pressure regulator valve (208). (Oil pump)
Was the problem found?Replace pressure
regulator valve
(208)
Go to Step 8
8Check for a stuck boost valve (205).(Oil pump)
Was the problem found?Replace boost
valve (205)
Go to Step 9
9Check for blocked intermediate oil passages to pressure
regulator valve. (Oil pump)
Was the problem found?
Replace oil pumpGo to Step 10
10Check for defective oil pump (9, 201, 202 & 209).
Was the problem found?
Replace oil pumpGo to Step 11
11Check for internal leaks.
– Check balls missing or out of location in valve bodies
– Seals cut or damaged
– Gaskets defective, etc.
Was the problem found?Install balls, or
correct ball
location
Replace seals
Replace gaskets
—

7A–21 AUTOMATIC TRANSMISSION (4L30–E)
Chart 15b: Possible Causes Of High Line Pressure
NOTE: If transmission is operating in backup mode, high
line pressure will be present.
Step
ActionYe sNo
1Check for defective throttle position sensor.
Was the problem found?Replace throttle
position sensor.
Go to Step 2.
2Check for a stuck force motor plunger (404). (Open
circuit/intermittent) (Adapter case valve body)
Was the problem found?Replace force
motor plunger
(404)
Go to Step 3
3Check for a stuck feed limit valve (412). (Adapter case valve body)
Was the problem found?Replace force
motor plunger
(412)
Go to Step 4
4Check converter bolts (4 & 5).
Was the problem found?Tighten converter
bolts (4 & 5)
Go to Step 5
5Check for a stuck pressure regulator valve (208). (Oil pump)
Was the problem found?Replace pressure
regulator valve
(208)
Go to Step 6
6Check for a stuck boost valve (205). (Oil pump)
Was the problem found?Replace boost
valve (205)
Go to Step 7
7Check for internal leaks.
– Check balls missing or out of location in valve bodies
– Seals cut or missing
– Gaskets defective, etc.
Was the problem found?Install balls, or
correct ball
location
Replace seals
Replace gaskets
—

7A–23 AUTOMATIC TRANSMISSION (4L30–E)
Stall Test
The stall test allows you to check the transmission for
internal abrasion and the one way clutch for slippage.
Torque converter performance can also be evaluated.
The stall test results together with the road test results will
identify transmission components requiring servicing or
adjustment.
Stall Test Procedure:
1. Check the level of the engine coolant, the engine oil,
and the automatic transmission fluid. Replenish if
necessary.
2. Block the wheels and set the parking brake.
3. Connect a tachometer to the engine.
4. Start the engine and allow it to idle until the engine
coolant temperature reaches 70 – 80
C (158 –
176
F).
5. Hold the brake pedal down as far as it will go.
6. Place the selector in the “D” range.
7. Gradually push the accelerator pedal to the floor.
The throttle valve will be fully open.
Note the engine speed at which the tachometer
needle stabilizes.
Stall Speed : 2,100
150 rpm
NOTE: Do not continuously run this test longer than 5
seconds.
8. Release the accelerator pedal.
9. Place the selector in the “N” range.
10. Run the engine at 1,200 rpm for one minute.
This will cool the transmission fluid.
11. Repeat Steps 7 – 10 for the “3”, “2”, “L” and “R”
ranges.
Line Pressure Test
The line pressure test checks oil pump and control valve
pressure regulator valve function. It will also detect oil
leakage.
Line Pressure Test Procedure:
1. Check the level of the engine coolant, the engine oil,
and the automatic transmission fluid.
Replenish if required.
2. Block the wheels and set the parking brake.
3. Remove the pressure detection plug at the left side of
the transmission case.
Set 5–8840–0004–0 pressure gauge and adapter to
the pressure detection plug hole.
241RS001
4. Start the engine and allow it to idle until the engine
coolant temperature reaches 70 – 80
C (158 –
176
F).
5. Hold the brake pedal down as far as it will go.
6. Place the selector in the “D” range.
7. Note the pressure gauge reading with the engine
idling.
8. Gradually push the accelerator pedal to the floor. The
throttle valve will be fully open.
Note the pressure gauge reading with the accelerator
pedal fully depressed.
NOTE: Do not continuously run this test longer than 5
seconds.
9. Release the accelerator pedal.
10. Place the selector in the “N” range.
11. Run the engine at 1,200 rpm for one minute.
This will cool the transmission fluid.
12. Repeat Steps 7 – 11 for the “3”, “2”, “L”, and “R”
ranges.
13. Install a pressure detection plug to the transmission
case, applying recommended thread locking agent
(LOCTITE 242) or its equivalent to thread of plug.
Make sure that thread is cleaned before applying
locking agents.
14. Tighten the pressure detection plug to the specified
torque.
Torque:9–14Nꞏm(0.9–1.4kgꞏm/7–10lbft)