check oil OPEL FRONTERA 1998 Workshop Manual

TRANSMISSION CONTROL SYSTEM (4L30–E)7A1–67
DTC P1850 Brake Band Apply Solenoid Malfunction
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Circuit Description
The brake band apply solenoid is a normally open
solenoid which controls the flow of fluid for brake band
application. The Powertrain Control Module (PCM)
uses Pulse Width Modulation (PWM) and changes
the duty cycle to control the solenoid. The PCM turns
the solenoid on (energized) and off (deenergized) at a
constant frequency. The length of time the solenoid is
energized during each on/off cycle is called the pulse
width. By varying or “modulating” the pulse width, the
solenoid output pressure is changed. Since the
solenoid is normally open, increasing the pulse width
increases the duty cycle and decreases the output
pressure. PWM control provides smooth band
application without an accumulator. The band is only
applied in first and second gears.
In the event of an electrical failure (open), the
solenoid regulates at the maximum oil flow (0% duty
cycle).
The solenoid is activated by current. This current is
produced by applying a voltage to one side (the High
side) and a ground to the other side (Low side).
The High Side Driver (HSD) is a circuit of the PCM
that acts as a switch between the solenoids and the
supply voltage. The High side of the solenoid is
permanently supplied with voltage. When the ignition
is off, the HSD is turned off.This DTC detects a continuous open or short to ground in
the brake band apply solenoid circuit or the brake band
apply solenoid. This is a type “D” DTC.
Conditions For Setting The DTC
Battery voltage is between 10 and 16 volts.
Ignition is “on”, Engine “run”.
The PCM commands the solenoid “on” and the
voltage remains high (B+) or the PCM commands the
solenoid “off” and the voltage remains low (zero
volts).
All conditions met in 1.3 seconds.
Action Taken When The DTC Sets
Inhibit brake band apply solenoid.
The PCM will not illuminate the CHECK TRANS
Lamp.
Conditions For Clearing The DTC
The DTC can be cleared from the PCM history by
using a scan tool.
The DTC will be cleared from history when the vehicle
has achieved 40 warmup cycles without a failure
reported.
The PCM will cancel the DTC default actions when
the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.

TRANSMISSION CONTROL SYSTEM (4L30–E)7A1–71
DTC P1860 TCC Solenoid Electrical
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Circuit Description
The PCM allows current to flow through the solenoid coil
according to the duty cycle (percentage of “on” and “off”
time). This current flow through the solenoid coil creates
a magnetic field that magnetizes the solid core. The
magnetized core attracts the check ball to seat against
spring pressure. This blocks the exhaust for the TCC
signal fluid and allows 2–3 drive fluid to feed to TCC signal
circuit. The TCC signal fluid pressure acts on the TCC
regulator valve to regulate line pressure and to apply fluid
pressure to the torque converter clutch shift valve. When
the TCC shift valve is in the apply position, regulated
apply fluid pressure is directed through the TCC valve to
apply the torque converter clutch. The TCC solenoid is
used in conjunction with the TCC solenoid to regulate fluid
to the torque converter. The TCC solenoid is attached to
the valve body within the transmission.
This DTC detects a continuous open or short to ground or
ignition in the TCC circuit or the TCC solenoid. This is a
type “D” DTC.
Conditions For Setting The DTC
Battery voltage is between 10 and 16 volts.
No shift solenoid A DTC P0753.
No shift solenoid B DTC P0758.
Ignition is “on”, Engine “run”.
The PCM commands the solenoid “on” and the
voltage remains low (zero volts).
The PCM commands the solenoid “off” and the
voltage remains high (B+).
All conditions met for 0.25 seconds.
Action Taken When The DTC Sets
Inhibit TCC engagement.
The PCM will not illuminate the CHECK TRANS
Lamp.
Conditions For Clearing The MIL/DTC
The DTC can be cleared from the PCM history by
using a scan tool.
The DTC will be cleared from history when the vehicle
has achieved 40 warmup cycles without a failure
reported.
The PCM will cancel the DTC default actions when
the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.
Diagnostic Aids
Inspect the wiring for poor electrical connections at
the PCM and at the transmission 16–way connector.
Look for possible bent, backed out, deformed or
damaged terminals. Check for weak terminal tension
as we ll. A lso ch eck fo r a ch af e d w ire th at cou l d s ho r t
to bare metal or other wiring. Inspect for a broken wire
inside the insulation.
When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
Test Description
The numbers below refer to the step numbers on the
diagnostic chart:
3. This test checks for voltage to the solenoid.
4. This test checks the ability of the PCM and wiring to
control the ignition circuit.
9. This test checks the resistance of the TCC solenoid
and the internal wiring harness.

7B–42MANUAL TRANSMISSION
5. Using a thickness gauge, measure the clearance
between the 4th block ring back and gear spline
end.
Standard: 0.75 – 1.65 mm (0.030 – 0.065 in)
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6. Check the braking effect of the block ring. Turn
the block ring in one direction while pushing it to
the gear cone. Check that the ring locks. If it does
not lock, replace the block ring.
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7. Install the needle roller bearing.
2. Reassemble the mainshaft assembly.
NOTE: Apply all parts with engine oil before installing
them.3. Inspect block ring
1. Using a thickness gauge, measure the clearance
between the synchronizer ring back and gear
spline end.
Gear
Standard Clearanse
1st0.80–1.60mm (0.032–0.063in)
2nd0.65–1.75mm (0.026–0.069in)
3rd0.75–1.65mm (0.030–0.065in)
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2. Turn the synchronizer ring in one direction while
pushing it to the gear cone. Check that the ring
locks.
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7B–64MANUAL TRANSMISSION
6. Check that the top gear shaft and mainshaft
rotate.
36. Install the transfer adapter.
1. Clean up the fitting surface.
2. Apply recommended liquid gasket (THREE
BOND 1281 or equivalent), as shown.
NOTE:
Don’t dry the liquid gasket.
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3. Using a plastic hammer, tap the transfer adapter
and attach it to the intermediate plate.
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4. Using 10 bolts, install the transfer adapter.
Torque: 37 Nꞏm (3.8 kgꞏm/27 lb ft)
NOTE:
Tighten the all bolts evenly.
Don’t damage the lip of the oil seal.
Install the wire clamp (9) to the transfer adapter.
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37. Install the gear control box.
1. Align the projection of the shift lever housing to
the shaft rod groove, and install the gear control
rod.
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7C–8CLUTCH
Diagnosis
ConditionPossible causeCorrection
DraggingFluid leakage.Repair
Air in hydraulic line.Bleed
Master cylinder and slave cylinder
seals worn. Replace master cylinder.
Replace slave cylinder seals.
Driven plate warped.Replace driven plate.
Diaphragm spring weakened or tip of
fingers worn. Replace pressure plate
Driven plate sticking on splines.Lubricate with grease or replace.
Clutch spline worn. Repair
Release bearing worn or damaged.Replace release bearing.
SlippingDriven plate facing worn or
oil–soaked.Replace driven plate and check for
leaks.
Diaphragm spring weakened.Replace pressure plate.
Pressure plate or flywheel warped.Correct or replace.
Master cylinder and slave cylinder
seals worn.Replace master cylinder.
Replace slave cylinder seals.
ChatteringEngine mounts loose or damaged.Tighten or replace.
Driven plate facing warped.Replace driven plate.
Surface of facing hardened.Replace driven plate
Driven plate facing oil soaked. Replace driven plate and check for
leaks.
Damper springs weakened or
broken. Replace.
Pressure plate or flywheel warped.Correct or replace.
NoisyReplace bearing binding.Correct, or replace if damaged, and
lubricate.
Replace bearing worn or damaged. Replace release bearing.
Release bearing poorly lubricated. Lubricate.
Pilot bearing worn.Replace pilot bearing.
Damper springs weakened or
broken.Replace driven plate.
Rivets of driven plate exposed.Replace driven plate.
Replace driven plate.Hydraulic line blocked.Clean out or replace.
Master or slave cylinders binding.Repair or replace as needed.

7C–12CLUTCH
Driven Plate Assembly
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Legend
(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)
1. Visually check the torsion spring for looseness,
breakage, and weakening.
2. If any of these conditions are discovered, the driven
plate assembly must be replaced.
3. Visually check the facing surfaces for cracking and
excessive scorching.
4. Visually inspect the facing surfaces for the presence
of oil or grease.
5. If any of these conditions are discovered, the facing
must be cleaned or replaced.
6. Check that the driven plate moves smoothly on the
transmission top gear shaft spline.
7. Minor ridges on the top gear shaft spline may be
removed with an oil stone.
Driven Plate Warpage
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Legend
(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)
1. Insert the clutch pilot aligner into the driven plate
splined hub.
2. The clutch pilot aligner J-24547 must be held
perfectly horizontal.
3. Set a dial indicator to the driven plate outside
circumference.
4. Slowly turn the driven plate.
5. Read the dial indicator as you turn the driven plate.
6. If the measured value exceeds the specified limit, the
driven plate assembly must be replaced.
Driven Plate Warpage
Standard: 0.7 mm (0.028 in)
Limit: 1.0 mm (0.039 in)

7C–14CLUTCH
Release Bearing
201RS011
1. Visually check the release bearing for excessive play,
noise and breakage.
2. If any of these conditions are discovered, the release
bearing must be replaced.
3. When replacing the release bearing, replace both the
wedge collar and wire ring at the same time.
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Legend
(1) Wire Ring
(2) Pressure Plate Assembly
(3) Wedge Collar
(4) T/M Side
(5) Release Bearing
(6) Engine Side
Wedge Collar
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1. Visually check the surfaces of the wedge collar
making contact with the release bearing for excessive
wear and damage.
2. Replace any exhibiting excessive wear or damage.
Shift Fork
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1. Visually check the surfaces of the shift fork making
contact with the release bearing for excessive wear
and damage.
2. Remove any minor stepping or abrasion from shift
fork with an oil stone.
3. Replace any exhibiting excessive wear or damage.

8A–18LIGHTING SYSTEM
Lighting Switch (Combination Switch)
Removal
1. Disconnect the battery ground cable.
2. Remove the instrument panel driver lower cover(5).
Refer to the Instrument Panel Assembly in Body
Structure section.
3. Remove seven screws to remove the steering
cowl(4).
4. Disconnect the SDM (air bag controller) connector
located at lower of the instrument panel driver lower
cover.
5. Remove four fixing screws and disconnect the driver
inflator module connector to remove the driver inflator
module(3).
CAUTION: When carrying a live inflator module,
make sure the bag opening is pointed away from
y o u . I n c a s e o f a n a c c i d e n t a l d e p l o y m e n t , t h e b a g w i l l
then deploy with minimal chance of injury. Never
carry the inflator module by the wires or connector
on the underside of the module.
When placing a live inflator module on a bench or
other surface, always face the bag and trim cover up,
away from the surface. This is necessary so that a
free space is provided to allow the air bag to expand
in the unlikely event of accidental deployment.
6. Remove the steering wheel(2).
Refer to the Steering Wheel in Steering section.
7. Disconnect the SRS coil assembly connector,
remove four fixing screws to remove the SRS coil
assembly(1).
8. Disconnect the lighting switch connector, remove four
fixing screws to remove the lighting switch(6).
825RS039
Installation
To install, follow the removal steps in the reverse order,
noting the following points.1. Check to see if the vehicle is in the straight driving
condition and turn the rotary section of the SRS coil
assembly provided to the upper surface of the lighting
switch (combination switch) counterclockwise fully
until it stops.
Then from where it stops, turn it back about 3
rotations to set the alignment marks(7) together
before installing the steering wheel.
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2. Tighten the steering shaft nut to the specified torque.
Torque: 34 Nꞏm (3.5 kgꞏm/25 lb ft)
3. When connect the double lock type of inflator module
connector, insert the connector completely and lock
at outside.
Imperfect locking may cause malfunction of SRS
system circuit.
4. When installing the steering cowl(11), be sure to pass
the harnesses through the route as shown in the
figure so that the starter switch harness(8), the
combination switch harness(9) and inflator module
harness(10) will not get caught.
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LIGHTING SYSTEM8A–29
Light NameRated PowerNumber of
BulbsLens ColorRemarks
Headlight60w/55w2WhiteHalogen
FrontTurn signal light21w2Whitecombination
lightClearance light5w2Amber
FRT fog light55w2WhiteHalogen
Taillight/Stoplight5w/21w2Red
RearBumperTurn signal light21w2Ambercombination
lightTaillight/Stoplight5w/21w2RedBodyTurn signal light21w2Amber
Backup light21w2White
RR fog light21w2Red
Side turn signal light5w2Amber
License plate lightBumper5w2White
Body5W1White
High mount stoplight——RedLED
Map light5w2White
Dome light10w1White
Luggage room light8w1White
Courtesy light3.8w2White
A/C SW60mA1
RR defogger SW0.84w1
Mirror defogger SW0.84w1
FRT fog light SW0.7w1
RR fog light SW0.7w1
Cruise (Set)1.4w1Meter
Cruise (Main)1.4w1Meter
Check trans3w1Meter
Anti-theft3w1Warning box
Turn signal1.4w2Meter
Golw1.4w1Meter
Water sedimenter1.4w1Meter
Indicator/High beam1.4w1MeterWa rnin g
lightABS1.4w1Meter
Check engine1.4w1Meter
Low fuel1.4w1Meter
4WD1.4w1Meter
Oil Pressure1.4w1Meter
Brake system1.4w1Meter
Charge1.4w1Meter
Seat belt2w1Meter
A/T shift position0.91w7Meter
A/T oil temp3w1Meter

C-1
C-1
C-1
C-1
H-9I-9
H-9
H-9
H-24
I-9
A11 A10 A14 A9F4
PCM:POWERTRAIN CONTROL MODULE
I-9H-26
I-9
I-9
I-9
P C M
0.5
O/L0.85
G/Y 0.85
G/Y0.85
G/W 0.85
G/W5.0
W
0.85
G/Y
0.5
O/B 0.5
P/G 0.5
GR/W0.5
O/L 0.5
O/B 0.5
P/G 0.5
L/Y0.5
L/Y3.0
B/Y
0.5
P/W
5 16 4 21
I-9
29 26
I-9
28
I-9
6
I-9
B-14H-12B-14C-3 3
8 2 1
4 1
3 21 25 156 C-10 10A
METER,GAUGE STARTER SW
(IG1)
METER
POWER
WINTER
CHECK
TRANS
A/T OIL
TEMP
POWER
WINTER
CHECK
TRANS
A/T OIL
TEMP
(W/TOD)
B-13B-13
(W/CRUISE CONTROL)
STOP
LIGHT
SWBRAKE
SWC-14 15A
STOP,A/T CONT BATT. (+)
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