coolant OPEL FRONTERA 1998 Workshop Manual

INDUCTION 6J – 7
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.
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6J – 10 INDUCTION
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
2
3
4
1
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket
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INDUCTION 6J – 11
INSPECTION AND RAPAIR
1. Visually check for cracks/clogs inside intake
manifold.
2. If foreign material is observed, it should be taken
out, and if there are some cracks on the intake
manifold, it must be replaced.
INSTALLATION
1. Install the intake manifold assembly, tighten bolts
and to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft) for bolt
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft) for nut
2. Install fuel pipe.
Torque: 4 Nꞏm (0.4 kgꞏm / 2.9 lb ft) for M16 nut
(Apply engine oil)
Torque: 13 Nꞏm (1.3 kgꞏm / 9.4 lb ft) for M10 cap nut
Torque: 14 Nꞏm (1.4 kgꞏm / 10 lb ft) for M10
(Apply engine oil)
3. Install two way check valve.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
4. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.
5. Install high pressure oil pipe, then tighten sleeve nut
to the specified torque.
Torque: 29 Nꞏm (3.0 kgꞏm / 21.7 lb ft)
6. Reconnect harness connector to MAP sensor, EGR
vacuum sensor, ETC sensor, Water thermo unit,
IAT sensor and EVRV sensor.
7. Install hoses to EGR valve, EGR vacuum sensor
and Water outlet of heater.
8. Connect PCV hose.
9. Install oil level gauge guide and fix it.
10. Install intercooler assembly.
Refer to “Intercooler” in this manual.
11. Install water hose to thermostat housing and fill with
engine coolant.
Model of Turbocharger IHI RHF5
Turbine Maximum Speed 180,000 rpm
Maximum Inlet Gas Temperature 800 °C (1472 °F)
Vibration Peak (G) criteria Maximum 4 (G) at Turbine Rotor Speed 140,000 rpm
Tolerance Limit of Compressor Blade Height Less then 0.5 mm (0.0197 in)
MAIN DATA AND SPECIFICATIONS

7A–5 AUTOMATIC TRANSMISSION (4L30–E)
Normal Operation Of 2000 4L30–E
Tr a n s m i s s i o n
Torque Converter Clutch (TCC)
Application Conditions:
The TCC is normally applied in 2nd, 3rd and 4th gears
only when all of the following conditions exist:
— The engine coolant temperature is above 70
C
(158
F).
— The brake pedal is released.
— The shift pattern requests TCC apply.
Moreover, TCC is always applied in 2nd, 3rd and 4th
gears when the transmission oil temperature is above
135
C (275F).
This mode should be canceled at 125
C (257F).
ATF Warning Lamp
The ATF warning lamp will be constantly on (not flashing)
if the transmission oil temperature is above 145
C
(293
F).
The ATF warning lamp goes off again when the
transmission oil temperature is below 125
C (257F).
Special Shift Pattern When The Engine Is
Cold:
A special shift pattern is activated when the engine
coolant temperature is below 70
C (158F). (3–4 shifts,
for example, are delayed for small throttle openings and
will occur a few MPH higher.)
Diagnosis
Introduction
The systematic troubleshooting information covered by
this Section offers a practical and systematic approach to
diagnosing 4L30–E transmission, using information that
can be obtained from road tests, electrical diagnosis, oil
pressure checks or noise evaluation.
The key to correcting a complaint is to make use of all of
the available symptoms and logically letting them direct
you to the cause.
When dealing with automatic transmission complaints, it
is best to gather as many symptoms as possible before
making the decision to remove the transmission from the
vehicle.
Frequently, the correction of the complaint does not
require removal of the transmission from the vehicle.
Driver Information
To analyze the problem fill out a complete description of
the owner’s complaint.
Please draw a circle around the right information and
complete the following form. (The next page is an
example of a completed form). You can draw a circle
around many numbers if you are not sure.

7A–11 AUTOMATIC TRANSMISSION (4L30–E)
Fluid Condition
FLUID CONDITION
NORMAL*CONTAMINATED
COLORRED OR LIGHT
BROWNBROWNNON–TRANSPARENT
/ PINKBROWN
DRAIN
REQUIRED?NOYESYESYES
CONTAMINA–
TIONNONEVery small amount of
foreign material in
bottom of panContamination by
coolant or other sourceLarge pieces of metal
or other foreign
material in bottom of
pan
CORRECT
LEVEL AND
CONDITION
1. LOW LEVEL:
A. Add fluid to
obtain proper
level & check for
external leaks.
B. Correct cause of
leak.
2. HIGH LEVEL:
– Remove excess
fluid– Remove both pans
– Change filter
– Flush cooler
– Add new fluid
– Check level– Repair/replace
radiator cooler
–Transmission
overhaul required
– Check for:
Damaged plates
and seals
Contaminated
solenoids
– Flush cooler
– Add new fluid
– Check level
–Transmission
overhaul required
– Flush cooler and
cooler lines
– Add new fluid
– Check level
*Fluid should be changed according to maintenance
schedule.
Te s t D r i v i n g
Some 4L30–E automatic transmission complaints will
require a test drive as a part of the diagnostic procedure.
Some codes will not set unless the vehicle is moving. The
purpose of the test drive is to duplicate the customer’s
complaint condition and set a current Powertrain Control
Module (PCM) trouble code. Perform this procedure
before each 4L30–E automatic transmission repair, and
again after repairs are made.
IMPORTANT:
Duplicate the condition under which the customer’s
complaint was observed.
Depending on the complaint, the line pressure gauge
and the scan tool may be required during the test
drive.
During the test drive, it is important to record all
necessary data from the areas being monitored, for
use in diagnosis. Also listen for and note any unusual
noises.
The following procedure should be used to test drive
4L30–E automatic transmission complaint vehicles:
1. Turn the ignition ON without starting the engine.
Check that the “CHECK TRANS” lamp comes on for
approximately 2 seconds and then goes out and
remains out.
If the lamp is flashing, GOTO Check Trans Indicator
in Transmission Control System (4L30–E) section.
If no serial data is present, GOTO OBD System
Check. Refer to Driveability and Emissions in
Engine section.
If the lamp stays ON or stays OFF, GOTO “Check
Trans” Check in Transmission Control System
(4L30–E) section.
2. Drive the vehicle. During the test drive, be sure that
the transmission achieves normal operating
temperature (approx. 20 minutes).
Allow the transmission to go through all of its gear
ranges, checking shift timing and firmness. Duplicate
the owner’s complaint condition as closely as
possible during the test drive.
3. If, during the test drive, the “CHECK TRANS” lamp
comes on, use the scan tool to check for trouble
codes.
4. If, during the test drive, a problem is felt, but the
“CHECK TRANS” lamp does not come on and no
trouble codes are present, drive the vehicle with the
PCM disconnected (manually shifting the vehicle).
In Manual L, the vehicle operates in first gear.
In Manual 2, the vehicle operates in third gear.
In Manual 3 or “D”, the vehicle operates in fourth
gear.
If the problem still exists with the PCM disconnected,
refer to Mechanical/Hydraulic Diagnosis in this
section.
5. If no problem has been found at this point, check all
underhood connections that supply power to the PCM
and ignition fuses. Physically and visually inspect all
the PCM harness connectors for loose or corroded
terminals. Inspect the PCM ground points.

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.
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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–59 AUTOMATIC TRANSMISSION (4L30–E)
56. Connect wiring harness harness assembly (52) to
converter clutch solenoid, force motor, and 5 pin
connector.
57. Install oil pan gasket, adapter case oil pan (53), and
twelve 10 mm screws.
Torque: 11 N
m (1.1 kgꞏm/96 lb in)
Rotate transmission, with bottom pan facing down.
58. Install mode switch (54), two 10 mm screws, selector
lever nut, and cover.
10 mm screw
Torque: 13 N
m (1.3 kgꞏm/113 lb in)
Nut
Torque: 23 N
m (2.3 kgꞏm/17 lb ft)
Adjust using setting tool, refer to Mode Switch in
this section.
59. Install O–ring (55) on turbine shaft.60. Install torque converter (56)
The converter assembly must be replaced under any
of the following conditions:
a. Evidence of damage to the pump assembly.
b. Metal particles are found after flushing the cooler
lines.
c. External leaks in hub weld area.
d. Converter pilot broken, damaged, or poor fit into
crankshaft.
e. Converter hub scored or damaged.
f. Internal failure in stator.
g. Contamination from engine coolant.
h. Excess end play.Rotate transmission, bell housing up. Spin
converter to insure proper fit.
61. Fill transmission through the overfill screw hole of oil
pan, using ATF DEXRON
–III. Refer to Changing
Transmission Fluid in this section.
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