Front ach OPEL FRONTERA 1998 Workshop Manual

ENGINE ELECTRICAL 6D – 21
Rectifier Assembly
1. Measure the resistance between each diode
terminal and aluminum diode fin in forward and
reverse directions with the connection of the tester
leads switched. The diodes are normal if resistance
is nearly zero ohms in one direction and is infinitely
high in the other direction.
2. If a diode has no resistance or equal resistance in
both directions, it is defective and should be
replaced together with the holder.
IC Regulator Assembly
Connect a variable resistor, two 12V batteries, a fixed
resistor, and a voltmeter to the IC regulator as shown in
illustration.
a. Measuring equipment specifications
1. Fixed resistor (R1) : 10 Ohms / 3W
2. Variable resistor (Rv) : 0 – 300 Ohms / 12W
3. Batteries (BAT1, BAT2) : 12V (2 Batteries)
4. DC voltmeter : 0 – 50V / 0.5 steps (4 Check points)
b. Measuring procedure
1. Measure the voltage “V1” across the first battery
(BAT1). If the reading is between 10 and 13 volts,
the battery is normal.
2. Measure the voltage “V3” across both the batteries
(BAT1, BAT2). If the reading is between 20 and 26
bolts, the batteries are normal.
3. Gradually increase the resistance of the variable
resistor from zero. Measure the voltage “V2” (the
voltage across the F and E terminals).
Check to see that the voltage across “V1” changes
at this time. If there is no change, the voltage
regulator is faulty and must be replaced.
4. Measure the voltage at “V4” (the voltage across the
variable resistor center tap and terminal E with the
variable resistor resistance held constant). The
measure voltage should be within the specified
(14.4 ± 0.3 volts) limits. If it is not, the regulator
must be replaced.
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
NOTE:
1) Never make battery connections with polarities
reversed, or battery will be shorted via the diodes.
This will cause damage to the diodes.
2) Do not connect generator B terminal to ground; it is
connected directly to the battery.
This cable will burn if it is connected to ground.
3) Make sure to disconnect the positive (+) terminal of
the battery when quick-charging battery.
Diodes may be damaged due to abnormal pulse
voltage generated by the quick charger.
4) When reassembling the front section to rear
section, insert a stiff wire into hole in the rear face
of the rear cover from the outboard side to support
the brush in raised position, then insert the front
section to which rotor is assembled.
5) Reassemble parts carefully to be sure they fit into
their original position, paying attention to the
insulated portions.
6) Wipe insulating tubes, washers and plates clean
and install them in position carefully to avoid getting
oil or grease on them.
066RS036
R
EBS
R1RV
BAT2 BAT1
V2V3
V4V1＋
−
＋
−
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6D – 22 ENGINE ELECTRICAL
1. Using a press with a socket wrench attached,
reassemble rotor and rear end cover assembly in
the front cover.2. Install pulley on the rotor.
Secure the pulley directly in the vise between two
copper plates, and tighten nut to the specified
torque.
Torque: 111 Nꞏm (82 lb ft)
066RS022
066RS010
MAIN DATA AND SPECIFICATIONS
General Specifications
Model LR160-734B LR-170-760
Battery voltage V 12
Rated output A 60 70
Direction of rotation Clockwise
(as viewed from pulley side)
Rated rotation speed rpm 5,000
Maximum speed rpm 18,000

6E–27 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Non-Emissions related
Dose not request illumination of any lamp
Stores a History DTC on the first trip with a fail
Stores Fail Record when test fails
Updates the Fail Record each time the diagnostic test
fails
Storing and Erasing Freeze Frame Data and Failure
Records
The data captured is called Freeze Frame data. The
Freeze Frame data is very similar to a single record of
operating conditions. Whenever the MIL is illuminated,
the corresponding record of operating conditions is
recorded to the Freeze Frame buffer.
Data from these faults take precedence over data
associated with any other fault. The Freeze Frame data
will not be erased unless the associated history DTC is
cleared.
Each time a diagnostic test reports a failure, the current
engine operating conditions are recorded in the
Failure
Records
buffer. A subsequent failure will update the
recorded operating conditions. The following operating
conditions for the diagnostic test which failed
typically
include the following parameters:
Engine Speed
Engine Load
Engine Coolant Temperature
Vehicle Speed
Intake Throttle Position
MAP
Injector Base Pulse Width
Loop Status
Data Link Connector (DLC)
The provision for communication with the contorl module
is the Data Link Connector (DLC). It is located at behind
the lower front instrument panel. The DLC is used to
connect to a Tech 2. Some common uses of the Tech 2
are listed below:
Identifying stored Diagnostic Trouble Codes (DTCs).
Clearing DTCs.
Performing out put control tests.
Reading serial data.
060RW046
Verifying Vehicle Repair
Verification of vehicle repair will be more comprehensive
for vehicles with OBD system diagnostic. Following a
repair, the technician should perform the following steps:
1. Review and record the Fail Records and/or Freeze
Frame data for the DTC which has been diagnosed.
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the Fail
Records and/or Freeze Frame data.
4. Monitor the DTC status information for the specific
DTC which has been diagnosed until the diagnostic
test associated with that DTC runs.
Following these steps are very important in verifying
repairs on OBD systems. Failure to follow these steps
could result in unnecessary repairs.
Reading Flash Diagnostic Trouble Codes
The provision for communicating with the Engine Control
Module (ECM) is the Data Link Connector (DLC). The
DLC is located in the front console box. It is used in the
assembly plant to receive information in checking that the
engine is operating properly before it leaves the plant.
The diagnostic trouble code(s) (DTCs) stored in the
ECM’s memory can be read either through a hand-held
diagnostic scanner plugged into the DLC or by counting
the number of flashes of the “Check Engine” Malfunction
Indicator Lamp (MIL) when the diagnostic test terminal of
the DLC is grounded. The DLC terminal “6” (diagnostic
request) is pulled “Low” (grounded) by jumpering to DLC
terminal “4”, which is a ground wire.
This will signal the ECM that you want to “flash” DTC(s), if
any are present. Once terminals “4” and “6” have been
connected, the ignition switch must be moved to the “ON”
position, with the engine not running.
The “Check Engine”MIL will indicate a DTC three times if
a DTC is present. If more than one DTC has been stored

6G – 6 ENGINE LUBRICATION
OIL COOLER ASSEMBLY
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove front exhaust pipe.
4. Remove heat protector.
5. Remove exhaust valve assembly.
6. Oil cooler assembly.
1) Remove water hose from water inlet and outlet
side.
2) Cloth should be put under the oil cooler to
prevent oil from flowing out.
3) Loosen fixing bolt then remove oil cooler
assembly.
Legend
(1) Oil cooler assembly
(2) Oil filter assembly
INSPECTION AND REPAIR
1. Inspect for corrosion, wear, and breaks on the oil
cooler core.
2. If a problem is found on the oil cooler core, the oil
cooler assembly must be replaced.
INSTALLATION
1. Oil cooler assembly
1) Tighten oil cooler fixing bolt to the specified
torque and install water hoses.
Torque: 29 Nꞏm (3.0 kgꞏm / 21.7 lb ft)
2. Install exhaust valve assembly to turbocharger
assembly and tighten to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm / 19.5 lb ft)3. Install front exhaust pipe to the exhaust valve.
To r q u e :
67 Nꞏm (6.8 kgꞏ.m / 49.2 lb ft)
(At exhaust valve side)
43 Nꞏm (4.4 kgꞏm / 32 lb ft)
(At center exhaust pipe side)
4. Install heater protector.
5. Fill engine coolant.
6. Connect battery ground cable.
7. Start engine and carefully check for leakage of oil
and coolant.
OIL COOLER SPECIFICATIONS
OIL FILTER
REMOVAL
1. Put container under the oil filter to prevent oil from
the oil filter from flowing out.
2. Use filter wrench to remove oil filter.
Filter wrench: 5-8840-0203-0
INSTALLATION
1. Apply engine oil thinly to oil filter O-ring.
2. Tighten oil filter by hand until O-ring comes in
contact with the sealing surface.
3. Use filter wrench to tighten oil filter one turn and 1/8
turn.
4. Start engine and carefully check for oil leakage from
oil filter.
SUB OIL FILTER
The sub oil filter requires no servicing until the
replacement interval is reached.
The element is designed to provide special filtering
efficiency until it becomes due for replacement.
It is recommended to check and replace the sub oil filter
when the engine is being overhauled or if it is broken
inside the engine.
1
2
050RW009

7A–30
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.
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5. Disconnect shift control rod (2) from the selector lever
assembly side.
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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.
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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)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–79
244RY00005
101RY00004
249RW003
242RW013
Look-up solenoid (Normal open type)
THROTTLE POSITION SENSOR
INSPECTION
1. Turn the starter switch to the "ON" position.
2. Measure the voltage between throttle position sensor
connector terminals 2 (output) and 3 (ground).
NOTE:
• Do not remove the sensor connector.
• Make sure that power source (4.75-5.25V) is measured
between terminals 1 and 3 before measurement at step
2).
ATF TEMPERATURE SENSOR
INSPECTION
1. Disconnect the front side ATF cooler pipe from the elbow
and remove the elbow.
2. Remove the ATF temperature sensor from the transmission
case.
3. Place the ATF temperature sensor in a container of ATF.
4. Measure the resistance between each terminals.
5. If either of the measured values exceeds the specified,
replace the ATF temperature sensor.
Nꞏm (kgꞏm/ lbꞏft)
When battery terminal is
disconnectedAir passes through
When battery terminal is
connectedNo air leaks
Throttle position Voltage (V)
Idle 0.25-0.45
WOT 3.74-4.56
Resistance 0.5 - 30 k
(0C - 120C)
Torque 15 (1.5/11)

7A–80 AUTOMATIC TRANSMISSION (AW30-40LE)
256RY00001
256RW012
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SELECTOR LEVER
INSPECTION
1. Make sure that when the selector 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.
REMOVAL
Preparation:
Diconnect negative (–) battery cable.
1. Transfer Control Lever Knob
2. Front Console
Disconnect wiring harness connectors.
3. Selector Lever Assembly
1) Disconnect shift lock cable from the selector lever
assembly side.
2) Disconnect wiring harness connectors.
3) Disconnect shift control rod from the selector lever
assembly side.

7A–88 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00026
022RY00001
11. Under cover and flex plate-torque converter bolt
• Remove the under cover.
• Turn the crankshaft to gain access to each bolt.
Remove the six torque cover ter fixing bolts.
NOTE:
New fixing bolts should be replaced for reassembly.
12. Rear mounting nut
• Support transmission with a jack.
• Remove two rear mounting nuts from the 3rd
crossmember.
13. 3rd crossmember
14. Oil level gauge and tube
15. Starter
• Remove the mounting bolts, and pull the star ter toward
the front of the vehicle.
Lay the star ter alongside the engine.
16. Engine-transmission bolt
• Remove engine-transmission fixing bolts.
• Disconnect the breather hose from the breather hose 3
way (W/TOD) or 2 way (WO/TOD).
17. Transmission assembly
NOTE:
Keep the oil pan positioned down.
Be careful not to let the torque converter slide out.