tow OPEL FRONTERA 1998 Owner's Manual

6A – 80 ENGINE MECHANICAL
3. Piston and Connecting Rod Assembly
1) Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins
and each piston ring and piston.
2) Align the front mark (2) of piston and front mark
(3) of connecting rod then assemble them.
3) The N mark of the piston ring is faced toward the
top, check to see that the piston ring end gap is
correctly positioned.
Legend
(1) 1st piston ring end gap
(2) 2nd piston ring end gap
(3) Oil ring end gap4) Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
Piston Ring Compressor: 5-8840-9018-0
5) Match the numbered caps with the numbers on
the connecting rods. Align the punched marks
on the connecting rods and caps.
6) Apply engine oil to the threads and seating faces
of the nuts.
7) Tighten the cap nuts in 2 steps, using angular
tightening method as shown in the following
specifications.
1st step: 29 Nꞏm (3.0 kgꞏm/22 lb ft)
2nd step: 45°– 60°
After tightening the cap nuts, check to see that
the crankshaft rotates smoothly
4. Piston Cooling Oil Pipe
If the piston cooling oil pipe is forcibly assembled,
the end of the oil jet may bend. It could make it
impossible to supply oil to the piston cooling holes,
which will sometimes cause piston seizure.
Sufficient care should be taken to pipe assembly
work.
1) Tighten the bolt and oil jet plug to the specified
torque.
Torque:
M6: 8 Nꞏm (0.8 kgꞏm/6 lb ft)
M8: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
Oiling Jet Plug: 30 Nꞏm (3.1 kgꞏm/22 lb ft)
5. Crank case
1) Refer to “Crank case” in this manual.
6. Apply liquid gasket (TB-1207C or equivalent) to
retainer then install it to rear end of cylinder block
within 5 minutes.
7. Crankshaft Rear Oil Seal
1) Tighten the adapter to the crankshaft rear and
section with 2 bolts.
2) Insert the oil seal into the peripheral section of
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) Check the dimension of the oil seal setting from
rear end of crankshaft.
Standard Dimension = 12.5 ± 0.3 mm
Oil Seal Installer: 5-8840-2359-0
2
3
1
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3
1
2
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ENGINE ELECTRICAL 6D – 3
ON-VEHICLE SERVICE
BATTERY CHARGING
Observe the following safety precautions when
charging the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during the
charging procedure.
Battery charging should be discontinued or the rate
of charge reduced if the battery feels hot to the
touch.
Battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas or
spew electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue
dot or ring, it may be necessary to jiggle or tilt the
battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be
either quick-charged or slow-charged in the same
manner as other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
JUMP STARTING
JUMP STARTING WITH AN AUXILIARY
(BOOSTER) BATTERY
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: Failure to carefully follow the jump
starting procedure could result in the following:
1. Serious personal injury, particularly to your
eyes.
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one or
both vehicles.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode. Remove any rings, watches, or other jewelry
before working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with your
eyes or skin.
Never allow battery fluid to come in contact with fabrics
or painted surfaces.
Battery fluid is a highly corrosive acid.Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface, immediately and
thoroughly rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of the reach of young
children.
JUMP STARTING PROCEDURE
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector lever in the “PARK”
position.
If the vehicle is equipped with a manual
transmission place the shift lever in the “NEUTRAL”
position.
Turn “OFF” the ignition.
Turn “OFF” all lights and any other accessory
requiring electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the
positive terminal of the discharged battery.
Do not allow the vehicles to touch each other.
This will cause a ground connection, effectively
neutralizing the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the
negative terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the A/C compressor
bracket or the generator mounting bracket) of the
vehicle with the discharged battery.
This ground connection must be at least 450 mm
(18 in) from the battery of the vehicle whose battery
is being charged.
WARNING: Never attach the end of the jumper
cable directly to the negative terminal of the dead
battery.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical
accessories have been turned “OFF”.
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above
directions in the reverse order.
Be sure to first disconnect the negative cable from
the vehicle with the discharged battery.

6E–214
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
6. Remove the fuel gauge unit.
Cover or plug the fuel tank to prevent dust, dirt, or
debris from entering the tank.
TS22911
Installation Procedure
1. Install the fuel gauge unit.
2. Install the fuel gauge unit retaining screws.
TS22911
3. Connect the wiring connector to the fuel gauge unit.
TS23771
4. Fill the fuel tank with fuel.
Tighten the fuel filler cap.
Check for leaks at the fuel gauge unit gasket.
5. Connect the negative battery cable.
Fuel Injectors
Removal and Installation Procedure
Refer to Engine Fuel in 4JX1 Engine Section.
Fuel Temperature Sensor
Removal Procedure
CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when servicing
fuel lines or connections. Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before disconnecting the fittings. The
towels will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
1. Disconnect the negative battery cable.
2. Remove the intercooler assembly.
3. Remove the cylinder head. Refer to engine
mechanical section.

INDUCTION 6J – 13
IHI SERVICE NETWORK
For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger Service
Facility.
HEADQUARTERS
ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD. (IHI)
General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN
TEL: 81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430
CHINA
IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, People’s R epublic of CHINA
TEL: 86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX: 210343 IHIPK CN
TA I WA N
IHI TAIPEI OFFICE
Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL: 886-(2)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
TLX: 11320 IHICO
THAILAND
IHI BANGKOK OFFICE
8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND
TEL: 66-(2)-236-3490, 7356, 9099
FAX: 66-(2)-236-7340
TLX: 82375 IHICO TH
MALAYSIA
IHI KUALA LUMPUR OFFICE
Letter Box No. 52, 22nd Floor, UBN Tower,
10 Jin. P. Ramlee 50250 Kuala Lumpur, MALAYSIA
TEL: 60-(3)-232-1255, 1271
FAX: 60-(3)-232-1418
TLX: IHI KLMA 20257
INDONESIA
IHI JAKARTA OFFICE
9th Floor, Skyline Building JI. M.H. Thamrin, No. 9, Jakarta, INDONESIA
TEL: 62-(21)-32-2147, 390-2211
FAX: 62-(21)-32-3273
TLX: 44175 IHIJKT

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)
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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–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–27 AUTOMATIC TRANSMISSION (4L30–E)
Changing Transmission Fluid
There is no need to change the transmission fluid unless
the transmission is used under one or more of the
following heavy duty conditions.
A. Repeated short trips
B. Driving on rough roads
C. Driving on dusty roads
D. Towing a trailer
If the vehicle is used under these conditions, change the
fluid every 20,000 miles (32,000 km.)
More over, the remaining life percentage of ATF can be
estimated by using Tech 2 as an auxiliary tool to judge the
right time for ATF replacement.
The remaining life percentage is calculated from ATF’S
heat history. When it is close to 0%, ATF replacement is
recommended.
1. Place a large drain pan under the oil pan.
2. Remove the transmission oil drain screw (2) and drain
fluid.
3. Tighten drain screw (2).
Torque: 38 N
m (3.9 kgꞏm/28 lb ft)
4. Remove the transmission overfill screw (1) and fill
transmission through overfill screw opening, using
DEXRON
–III ATF.
NOTE: Add transmission fluid until it flows out over the
overfill screw opening.
5. Let engine idle until a fluid temperature between 32
C
(90
F) and 57C (135F) is reached.6. Add transmission fluid until it flows out over the overfill
screw opening, then close the overfill screw (1).
To r q u e : 3 8 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
service scan tool.
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Selector Lever
Inspection
1. Make sure that when the shifter control 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 in illustration.
C07RW009

7A–51 AUTOMATIC TRANSMISSION (4L30–E)
25. Install snap ring (23) in adapter case.
Install 5–8840–0195–0 (J–23327) and
5–8840–2263–0 (J–23327–90) fourth clutch spring
compressor.
Seat snap ring in groove.
Remove compressor.
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26. Install selective washer using petroleum jelly.
27. Install two O–ring seals (24) in main case and adapter
case/main case seal ring (25).28. Install 5–8840–2268–0 (J–38588) guide pins.
Install adapter case and center support assembly to
main case.
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29. Install thrust washer (26) into adapter case, with
tangs pointing downwards.
30. Preassemble overdrive internal gear (27) and thrust
bearing assembly (28) onto the turbine shaft and
overrun clutch assembly.
NOTE: Install bearing assembly, black side up. Use
petroleum jelly to keep assembly in place.
31. Install overdrive carrier (30) and internal gear
assembly into adapter case.
32. Install fourth clutch plates (29) in the following order:
Steel, Lined, Steel, Steel, Lined, Steel. Steel plates
go in with short tang facing towards valve body
surface.

7A–52
AUTOMATIC TRANSMISSION (4L30–E)
33. Install fourth clutch retainer (31) with the notch facing
up and positioned towards valve body surface.
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34. Overdrive clutch end play measurement
1. Install the 5–8840–2262–0 (J–23085–A)
selective washer gauging tool on the adapter
case flange and against the input shaft.
2. Position the inner shaft of the tool against the
thrust surface of the overrun clutch housing.
3. Tighten thumb screw. Remove the tool.
4. Measure gap. Select appropriate size washer as
shown in the chart.
5. Set selective thrust washer aside.
Selective Thrust Washer
Gap: mm(in)Color
1.53 – 1.63 (0.060 – 0.064)Yellow
1.72 – 1.82 (0.068 – 0.072)Red
1.91 – 2.01 (0.075 – 0.079)Black
2.10 – 2.20 (0.083 – 0.087)Natural
2.29 – 2.39 (0.090 – 0.094)Green
2.48 – 2.58 (0.098 – 0.102)Blue
FOLLOWING THE PROCEDURE SHOULD RE-
SULT IN FINAL END–PLAY FROM 0.1 mm TO 0.8
mm (0.004 in TO 0.03 in)
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35. Install selective washer (32).
NOTE: Use petroleum jelly to hold selective washer in
place.
36. Install gasket (33).
37. Install converter housing and oil pump assembly (34)
to adapter case.
Fit and tighten seven outer 13 mm screws.
To r q u e : 3 9 N
m (4.0 kgꞏm/29 lb ft)

7A–54
AUTOMATIC TRANSMISSION (4L30–E)
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43. Main case end play measurement.
1. Attach axial play checking tool on the extension
housing and set indicator to zero on output shaft.
2. Manually push output shaft upwards.
End play: 0.36mm – 0.80mm (0.014 in – 0.031in)
3. Remove axial play checking tool.
4. If end play is not correct, repeat selective washer
selection.
241RS005
44. Inspect servo piston seal ring. Replace if necessary.
Ensure brake band is correctly positioned. Rotate
output shaft if necessary.
Install 5–8840–2274–0 (J–38428) servo piston
fitter in servo bore.
Install apply rod (40), round end toward band, return
spring (41) and piston assembly (42).
45. Install the 5–8840–0501–0 (J–23075) servo spring
compressor with offset to rear of case.
Compress servo piston seal ring, using fitter while
tightening the tool screw.
Install servo piston retaining ring (43).
Remove tool.
Adjust the brake band by tightening the servo
adjusting screw to 4.5 Nꞏm torque. Be certain the
lock nut is loose, then back–off the screw five turns
exactly. Hold piston sleeve with wrench and tighten
lock nut to 18.5 Nꞏm torque. Be certain the adjusting
screw does not turn.