wheel OPEL FRONTERA 1998 Workshop Manual

ENGINE MECHANICAL 6A – 97
11. Use the special tool to install the crankshaft front oil
seal to timing gear case.
Front Oil Seal Installer: 5-8840-2061-0
1) Check fit-of the oil seal and gear case cover at
the front end.
Standard: 0.5 – 2.5 mm (0.0197 – 0.0984 in)
NOTE: Apply engine oil to oil seal lip before installation
of the seal.
12. Install the oil pan assembly to original position and
tighten to specified torque.
Torque: 22 Nꞏm (2.2 kgꞏm/15.9 lb ft)
13. Crankshaft Rear Oil Seal
1) Tighten the adapter to the crankshaft rear end
with 2 bolts.
2) Insert the oil seal into the adapter.
3) Insert the sleeve into the adapter and tighten it
with a bolt (M12 x 1.75L = 70) until the adapter
hits the sleeve.
4) Remove the adapter and the sleeve.
5) With the seal pressed in, check the dimension of
the oil seal outside end and crankshaft end.
Standard Dimension = 12.5 ± 0.3 mm
Oil Seal Installer: 5-8840-2359-014. Cylinder Block Rear Plate (A/T Model)
1) Tighten the cylinder block rear plate fixing bolts
to the specified torque.
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
15. Flywheel Housing (M/T Model)
1) Install flywheel housing aligned with the dowel
pin on the cylinder block.
2) Tighten the flywheel housing fixing bolts to the
specified torque.
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
16. Flywheel
1) Refer to “Crankshaft” in this manual.
17. Cylinder Head Assembly
1) Refer to “Cylinder Head” in this manual.
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12.5 + 0.3–
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6A – 98 ENGINE MECHANICAL
OIL PUMP ASSEMBLY
2
1
5
6
3
4
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Legend
(1) Flywheel
(2) Rear Plate (A/T)
(3) First Oil Pump Assembly(4) Second Oil Pump Assembly
(5) O-Ring (For first oil pump)
(6) O-Ring (For second oil pump)
REMOVAL
1. Disconnect battery ground cable
2. Lift up car
3. Drain engine oil
NOTE: Install drain plug with new gasket.
4. Flywheel
5. Rear Plate (A/T) or Flywheel Housing (M/T)
6. First Oil Pump Assembly and Second Oil Pump
Assembly
1) Remove oil pump assembly from cylinder block
and crankcase.
INSTALLATION
1. First oil pump assembly
1) Set O-ring to oil pump.
2) Install oil pump drive gear to the rear end of the
balance shaft RH.
3) Apply engine oil to pump gear, install pump gear
to rear end of cylinder block with specified
torque.Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
2. Second oil pump assembly
1) Set O-ring to oil pump.
2) Install oil pump drive gear to the rear end of the
balance shaft LH.
3) Apply engine oil to pump gear, install pump gear
to rear end of crank case with specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
3. Install rear plate (A/T) or flywheel housing (M/T)
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
4. Install flywheel
1) Apply engine oil to bolt and tighten with angular
tightening method.
First step: 59 Nꞏm (6.0 kgꞏm/43 lb ft)
Second step: 60° to 90°

6E–19 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Component Locator
Engine Component Locator Table
F06RW051
NumberNameLocation
1AP (Accelerator Pedal Position) SensorAP Bracket
2CKP (Crankshaft Position) SensorInside the right front flywheel Housing
3Oil RailMounted on the camshaft carrier
4Oil (Rail) Pressure SensorMounted on the Oil Rail
5OT (Oil Temperature) SensorMounted on the Oil Rail
6Fuel InjectorIn the Cylinder Head Cover
7Fuel Return OrificeInside the Cylinder Head
8FT (Fuel Temperature) SensorFuel Return Adaptor
9IntercoolerOn the Cylinder Head Cover
10Intake Throttle MotorBehind the Intake Manifold
11Intake ThrottleBehind the Intake Manifold
122 Way Check ValveBelow the Intake Manifold
13VSV (Vacuum Switching Valve)At the left Cylinder Body
14EGR Pressure SensorBelow the Intake Manifold
15Fuel FilterAt the left Engine Room
16CMP (Camshaft Position) SensorOn the forward of Timing Gear Case
17IAT (Intake Air Temperature) SensorBelow the Intake Manifold
18ECT (Engine Coolant Temperature)Thermostat Housing
19High Pressure Oil PumpOn the back Timing Gear Case

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)
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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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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–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–32
AUTOMATIC TRANSMISSION (4L30–E)
4. Disconnect shift lock cable from the selector lever
assembly side.
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5. Disconnect wiring harness connectors.
6. Disconnect shift control rod from the selector lever
assembly side.
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7. Remove selector lever assembly (3).
8. Remove transfer control lever (4).
9. Remove transfer and exhaust protector (5).
10. Remove rear propeller shaft (6).
11. Remove front propeller shaft (7).
12. Remove harness protector (8).
13. Support transfer case with a jack and remove two rear
mount nuts (9) from the 3rd crossmember side.
14. Remove eight third crossmember bolts and third
crossmember (10).
15. Disconnect one oxygen sensor connector from the
transmission harness.
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16. Remove exhaust pipe (11).
17. Disconnect transmission oil cooler pipe (12) from A/T
side.
18. Remove oil pipe clamp from torque converter
housing bracket.
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19. Loosen oil pipe clamp bolt at the engine mount side.
20. Remove starter (13).
21. Disconnect fuel pipe clamp bracket from
transmission side.
22. Disconnect transmission harness connectors (14)
from transmission, and transfer.
23. Remove flywheel under covers (3 pieces) (15) from
transmission case.
24. Lower the front of the transmission a little, then
remove flywheel torque converter fixing bolts (6
pieces) (16) by turning crankshaft.
25. Support the transmission with a transmission jack,
and hoist engine with a chain block.
26. Remove engine transmission fixing bolts (17).

7A–33 AUTOMATIC TRANSMISSION (4L30–E)
27. Remove transmission assembly (18).
Installation
1. Slowly raise transmission jack until front of the
transmission is aligned with rear of the engine, then
install transmission assembly.2. Tighten engine transmission bolts to the specified
torque.
F07RW041
3. Support transfer case with a jack, and remove the
transmission jack.
4. Install flywheel torque converter bolts (6 pieces) by
turning crankshaft.
Torque: 54 N
m (5.5 kgꞏm/40 lb ft)
NOTE: Do not reuse the flywheel torque converter bolt.
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7A–34
AUTOMATIC TRANSMISSION (4L30–E)
5. Install the flywheel under cover (3 pieces), and tighten
the bolts to the specified torque.
Torque: 8 N
m (0.8 kgꞏm/69 lb in)
6. Install the starter, and tighten the bolts to the specified
torque.
Torque: 40 N
m (4.1 kgꞏm/30 lb ft)7. Connect transmission harness connectors to
transmission, and transfer.
8. Connect fuel pipe bracket to transmission side.
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9. Install transmission oil cooler pipe to transmission.
Torque: 54 N
m (5.5 kgꞏm/40 lb ft)
10. Install oil pipe clamp to torque converter housing
bracket.
11. Tighten oil pipe clamp bolt at engine mount side.
12. Install exhaust pipe, and tighten the bolts to the
specified torque.
Exh. pipe to exh. manifold 67 N
m
(6.8 kgꞏm/49 lb ft)
Exh. pipe flange bolt 43 N
m (4.4 kgꞏm/32 lb ft)13. Connect one oxygen sensor connector to the
transmission harness.
14. Install third crossmember, and tighten the bolts to the
specified torque.
To r q u e : 5 0 N
m (5.1 kgꞏm/37 lb ft)
15. Install rear mount nuts, and tighten the nuts to the
specified torque.
To r q u e : 5 0 N
m (5.1 kgꞏm/37 lb ft)
16. Remove the jack from the transfer case.