1998 OPEL FRONTERA 2000

INDUCTION 6J – 5
REMOVAL
2. Drain engine coolant.
3. Remove air cleaner cover and air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove water pipe from water inlet of
turbocharger.
6. Remove oil pipe.
1) Remove fixing bolts from oil inlet of turbocharger
then remove oil pipe.
2) Plug open port of turbocharger to prevent
foreign materials from entering the turbocharger.
7. Remove oil drain pipe from turbocharger.
8. Remove water outlet pipe from turbocharger.
9. Remove heat protector.
10. Remove exhaust valve assembly.
11. Remove turbocharger fixing nuts from exhaust
manifold then remove turbocharger assembly.
For Europe
025R200006

INDUCTION 6J – 7
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
For Europe
025R200007
For Europe
025R200006

6J – 8 INDUCTION
7. Water inlet pipe.
1) Install water inlet pipe with a new gasket, tighten
bolts to the specified torque.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
8. Install intercooler assembly.
Refer to “Intercooler” in this manual.
9. Install air cleaner cover with air duct.
10. Fill engine coolant to full level.
11. Install battery and connect battery cable.
For Europe
025R200007

INDUCTION 6J – 9
INTERCOOLER
REMOVAL
1. Disconnect battery ground cable.
2. Remove air cleaner cover with air duct.
3. Remove intercooler cover.
4. Intercooler assembly.
1) Remove rubber hose from intercooler outlet
side.
2) Remove rubber hose from intercooler inlet side.
3) Remove four fixing bolts and remove intercooler
assembly.
INSPECTION AND REPAIR
1. Visual check for clogs in the fins.
2. Check for brokens on the tube.
3. If any problem on the intercooler is observed during
inspection, clean or replace the intercooler.
INSTALLATION
1. Intercooler assembly.
1) Connect outlet hose to intake manifold.
Tighten hose clamp to the specified torque.
Torque: 4 Nꞏm (0.4 kgꞏm / 3 lb ft)
2) Connect inlet hose to the turbocharger outlet
side.
Tighten hose clamp to the specified torque.
Torque: 4 Nꞏm (0.4 kgꞏm / 3 lb ft)
3) Install intercooler assembly, tighten fixing bolts
to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
2. Install intercooler cover.
3. Install air cleaner cover and air duct.
4. Connect battery ground cable.
For Europe
2
33
1
Legend
(1) Air Cleaner Cover and Air Duct
(2) Intercooler Cover
(3) Intercooler Assembly
135R200003

INDUCTION 6J – 11
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
For Europe
2
1
3
3 1 42
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket
025R200005
3124
025RW031

7A–70
AUTOMATIC TRANSMISSION (4L30–E)
3–4 Accumulator Piston
Disassembled View
244RS005
Legend
(1) Snap Ring
(2) Cover(3) Spring
(4) Piston Assembly
Disassembly
1. Install the 5–8840–2277–1 (J–38559–A) cover
compressor on adapter case.
Compress piston cover then remove snap ring.
242RW009
2. Install the 5–8840–2403–0 (J–41096) cover remover
and 5–8840–2266–0 (J–38584) adapter to center
hole of cover.
Use the 5–8840–0019–0 and 5–8840–2000–0
(J–23907) slide hammer to remove cover.
3. Remove spring and piston assembly.
242RW010
Inspection And Repair
Visual Check:
If any damage, deformation or wear is found, replace the
damaged part.

7A–83 AUTOMATIC TRANSMISSION (4L30–E)
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2282–0
(J–36797)
A/T extension housing
oil seal installer (Inside)
5–8840–0003–0
(J–3289–20)
Holding fixture base
5–8840–0004–0
Pressure gauge
5–8840–0618–0
(J–24773–1)
End play fixture (Use
with 5–8840–2271–0
(J–25022))
5–8840–0019–0 &
5–8840–2000–0
(J–23907)
Slide hammer

220R200001
220LV019