1998 OPEL FRONTERA oil level

6J – 12 INDUCTION
INSPECTION AND RAPAIR
1. Visually check for cracks/clogs inside intake
manifold.
2. If foreign material is observed, it should be taken
out, and if there are some cracks on the intake
manifold, it must be replaced.
INSTALLATION
1. Install the intake manifold assembly, tighten bolts
and to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft) for bolt
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft) for nut
2. Install fuel pipe.
Torque: 4 Nꞏm (0.4 kgꞏm / 2.9 lb ft) for M16 nut
(Apply engine oil)
Torque: 13 Nꞏm (1.3 kgꞏm / 9.4 lb ft) for M10 cap nut
Torque: 14 Nꞏm (1.4 kgꞏm / 10 lb ft) for M10
(Apply engine oil)
3. Install two way check valve.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
4. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.
5. Install high pressure oil pipe, then tighten sleeve nut
to the specified torque.
Torque: 29 Nꞏm (3.0 kgꞏm / 21.7 lb ft)
6. Reconnect harness connector to MAP sensor, EGR
vacuum sensor, ETC sensor, Water thermo unit,
IAT sensor and EVRV sensor.
7. Install hoses to EGR valve, EGR vacuum sensor
and Water outlet of heater.
8. Connect PCV hose.
9. Install oil level gauge guide and fix it.
10. Install intercooler assembly.
Refer to “Intercooler” in this manual.
11. Install water hose to thermostat housing and fill with
engine coolant.
Model of Turbocharger IHI RHF5
Turbine Maximum Speed 180,000 rpm
Maximum Inlet Gas Temperature 800 °C (1472 °F)
Vibration Peak (G) criteria Maximum 4 (G) at Turbine Rotor Speed 140,000 rpm
Tolerance Limit of Compressor Blade Height Less then 0.5 mm (0.0197 in)
MAIN DATA AND SPECIFICATIONS

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–10
AUTOMATIC TRANSMISSION (4L30–E)
Checking Transmission Fluid Level
and Condition
Checking fluid level and condition (color and odor) at
regular intervals will provide early diagnosis information
about the transmission. This information may be used to
correct a condition that, if not detected early, could result
in major transmission repairs.
IMPORTANT:When new, automatic transmission fluid
is red in color. As the vehicle is driven, the transmission
fluid will begin to look darker in color. The color may
eventually appear light brown.
A dark brown color with burnt odor may indicate
excessive fluid deterioration and signal a need for fluid
change.
Fluid Level
When adding or changing fluid, use only DEXRON –III.
Refer to Maintenance and Lubrication in General
Information section for maintenance information and
servicing interval.
CAUTION: DO NOT OVERFILL.
Overfilling will cause foaming, loss of fluid, abnor-
mal shifting and possible damage to the transmis-
sion.
1. Park the vehicle on level ground and apply the parking
brake firmly.
2. Check fluid level with engine running at idle.
NOTE: Be sure that transmission fluid temperature is
below 30
C (86F).
3. Move the selector lever through all gear ranges.
4. Move the selector lever to “Park”.
5. Let engine idle for 3 minutes and open the overfill
screw (1).
6. Add released transmission fluid until it flows out over
the overfill screw opening.
7. Let engine idle until a fluid temperature between 32
C
(90
F) and 57C (135F) is reached, then close the
overfill screw (1).
Torque: 38 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 scan
tool.
Minimum fluid level
57C (135F)
Maximum fluid level
32C (90F)
242RW003
CAUTION: Do not open overfill screw with engine
stopped.
CAUTION: DO NOT CHECK FLUID LEVEL UNDER
THESE CONDITIONS:
Immediately after driving at sustained highway
speeds.
In heavy city traffic during hot weather.
If vehicle is towing a trailer.
If the vehicle has been operated under these conditions,
shut the engine off and allow the vehicle to “cool” for thirty
(30) minutes. After the cool down period, restart the
vehicle and continue from step 2 above.

7A–19 AUTOMATIC TRANSMISSION (4L30–E)
Chart 13: Shudder Only During Torque Converter Clutch (TCC) Applying
StepActionYe sNo
11. TCC shudder is one of the most commonly misdiagnosed
conditions in an automatic transmission. The key to
diagnosing TCC shudder is to note when it happens and under
what conditions. Once the TCC has been fully applied, it is
nearly impossible to make it shudder. TCC shudder (short
burst of noise normally less than 1 second) will only occur
during clutch applying. It is not a steady state condition.
2. Drive until whole drivetrain is at normal operating temperature.
– On 4WD vehicles, the test must be performed with transfer
case selector lever in “2H” position.
– Shudder is a short burst of noise normally less than 1 second
in duration, and can be induced by the following maneuver:
3. From coast condition at 50 mph in “D” range (Normal mode),
depress the throttle to 1/4-1/3 throttle. If present, shudder will
occur within 5 seconds together with TCC application.(The
scan tool may be used to determine the exact time of TCC
applying)
Was the problem found?
Replace
transmission fluid
and filter (remove
both pans) and
flush cooler lines.
Replace
converter
assembly and
O-ring on turbine
shaft
Perform
mechanical
inspection of
other drivetrain
components.
Chart 14: Possible Causes Of Transmission Noise
CAUTION: Before checking transmission for what
is believed to be transmission noise, ensure
presence and positioning of insulating plugs, pads
etc. Also make sure that noise does not come from
other drivetrain components.
Condition
Possible causeCorrection
Whine or BuzzOil level lowFill with ATF, check for external
leaks.
Plugged or restricted oil filterInspect oil filter.
Replace oil filter or ATF as necessary.
Damaged oil filter gasketReplace oil filter gasket.
Knocking noise from front of
transmission
Loose bolts (Converter to flex plate)Tighten to specifications.
transmission.Cracked or broken flex plateReplace flex plate.
Converter damagedReplace converter.
Knocking noise while driving, mostly
on acceleration.Transmission mount loose or brokenTighten mount bolts or replace
transmission mount.
Cooler line mounts loose or brokenTighten or replace cooler line
mounts.
Cooler lines touching body or frameRepair or replace as necessary.
Knocking noise when vehicle is
stationary
Loose flex plate mounting boltsTighten to specifications.
stationary.Cracked or broken flex plateReplace flex plate.
Damaged converterReplace converter.

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–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
240RS002
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) Oil Drain Plug 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–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)

7A–28
AUTOMATIC TRANSMISSION (4L30–E)
Removal
1. Disconnect battery ground cable.
2. Remove transfer control lever knob.
3. Remove front console.
Disconnect wiring harness connectors from front
console.
4. Disconnect shift lock cable (1) from the selector lever
assembly side.
256RW012
5. Disconnect shift control rod (2) from the selector lever
assembly side.
256RW013
6. Disconnect wiring harness connectors from the
selector lever assembly.
7. Remove selector lever assembly.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
Adjustment of select lever and control rod
1. Place the vehicle on a level surface.NOTE: If the vehicle is not on level surface, the shift
select cable set positions will vary with the movement of
engine. To prevent possible misadjustment of the cable,
the vehicle must be placed on a level surface.
2. Install the shift control rod (1) to the transmission
select lever (2), and then place the lever in the “N”
position.
3. Set select lever in the “N” position.
4. Push select lever forward (“R” position side) and
s e c u r e i t ( u s i n g a r u b b e r b a n d ( 3 ) , e t c . ) s o t h a t t h e p i n
comes into contact with the wall of the detent plate.
5. Install the shift control rod (1) to the selector lever arm
(4).
To r q u e : 3 2 N
m (3.3 kgꞏm/24 lb ft)
NOTE: Do not apply oil to the threaded portions.
256RW014
6. After adjustment, make sure that the selector lever
operates normally, and that each selector position is
properly indicated. (The red mark shows through the
window.)
Adjustment of shift lock cable
1. Set ignition key in “LOCK” position and selector lever
in “P” position.
2. Adjust cable screw cap on selector lever side to
provide a gap (slack for cable) of 1 – 2 mm between
rod on steering lock side and stopper.
Adjust cap as follows:
a. Pull screw cap (1) in arrow direction to remove
inner cable slack.
b. With cable kept as (a), adjust gap between nut (2)
and bracket to 5 mm (0.2 in).
c. Lock inner cable by turning nut (3) while holding nut
(2) in place.
Torque : 3.7 N
m (38 kgꞏcm/33 lb in)
NOTE: Clean the cable threads, and do not apply oil to
them.