Gas OPEL FRONTERA 1998 Workshop Manual

6F – 2 ENGINE EXHAUST
GENERAL DESCRIPTION
150RW070
When inspecting or replacing exhaust system
components, make sure there is adequate clearance
from all points on the underbody to prevent overheating
of the floor pan and possible damage to the passenger
compartment insulation and trim materials.
Check complete exhaust system and nearby body
areas and rear compartment lid for broken, damaged,
missing or mispositioned parts, open seams, holes
loose connections or other deterioration which could
permit exhaust fumes to seep into the rear
compartment or passenger compartment. Dust or water
in the rear compartment may be an indication of a
problem in one of these areas. Any faulty areas should
be corrected immediately.HANGERS
Various types of hangers are used to support exhaust
system(s). These include conventional rubber straps,
rubber rings, and rubber blocks.
The installation of exhaust system supports is very
important, as improperly installed supports can cause
annoying vibrations which can be difficult to diagnose.
GASKET
The gasket must be replaced whenever a new exhaust
pipe, muffler or exhaust throttle is installed.

ENGINE EXHAUST 6F – 3
ON-VEHICLE SERVICE
FRONT EXHAUST PIPE
Rattles and noise vibrations in the exhaust system are
usually caused by misalignment of parts. When aligning
the system, leave all bolts or nuts loose until all parts
are properly aligned; then tighten, working from front to
rear.
1. Check connections for looseness or damage,
especially for exhaust gas leakage.
2. Check clamps and rubbers for weakness, cracks or
damage.3. If any part of the converter heat shield is damaged
or dented to the extent that it contacts the catalyst,
repair or replace.
4. Check for dents or damage and for any holes or
cracks caused by corrosion.
3
2 1
Legend
(1) Front exhaust pipe
(2) Center exhaust pipe
(3) Mounting rubber
150RW071

6J – 4 INDUCTION
TURBOCHARGER
REMOVAL
2. Drain engine coolant.
3. Remove air cleaner cover and air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove water pipe from water inlet of
turbocharger.
6. Remove oil pipe.
1) Remove fixing bolts from oil inlet of turbocharger
then remove oil pipe.
2) Plug open port of turbocharger to prevent
foreign materials from entering the turbocharger.
7. Remove oil drain pipe from turbocharger.
8. Remove water outlet pipe from turbocharger.
9. Remove heat protector.
10. Remove exhaust valve assembly.
11. Remove turbocharger fixing nuts from exhaust
manifold then remove turbocharger assembly.
9875 63
21
4
Legend
(1) Exhaust Manifold
(2) Gasket
(3) Turbocharger Assembly
(4) Water Hose(5) Water Hose
(6) Heat Protector
(7) Oil Pipe
(8) Oil Pipe
(9) Gasket
025RW023
036RW006

6J – 6 INDUCTION
Legend
(1) Pressure gauge
(2) Waste gate control rod
4) Check for cracks or breaks on the hose, if a
problem is found, the hose must be replaced.
CAUTION: Do not apply more than 120 Kpa (900
mmHg / 18.7 PSi) to waste gate actuator.
INSTALLATION
1. Install turbocharger assembly to exhaust manifold,
tighten to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm / 19.5 lb ft)2. Install exhaust valve assembly to outlet of
turbocharger, tighten bolts to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm / 19.5 lb ft)
3. Install heat protector.
4. Water inlet pipe.
1) Tighten water inlet pipe with new gasket.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
5. Oil drain pipe.
1) Tighten oil drain pipe with new gasket.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
6. Oil inlet pipe.
1) Apply about 100 cc engine oil to turbocharger
housing before installing the oil pipe.
2) Turn the turbine shaft by hand to lubricate the
bearing.
3) Install the oil inlet pipe with a new gasket, tighten
bolt to the specified torque.
Torque: 22 Nꞏm (2.2 kgꞏm / 15.9 lb ft) For M10
Torque: 54 Nꞏm (5.5 kgꞏm / 39.8 lb ft) For M14
2
1
036RW011
036RW005
036RW006

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.
036RW005

INDUCTION 6J – 9
REMOVAL
1. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
2. Remove harness connector from motor and ITP
sensor.
3. Loosen the two fixing nuts and remove the throttle
valve assembly.
Legend
(1) Motor
(2) Intake Throttle Valve
(3) ITP sensor
INSPECTION AND REPAIR
1. Check for catching somwhere on the throttle valve.
2. If some problem is discovered during inspection on
the throttle valve, the throttle valve must replace.
INSTALLATION
1. Put gasket on the intake manifold and install throttle
valve.
2. Tighten nuts to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
3. Reconnect harness connector to motor and
ITPsensor.
4. Install intercooler assembly.
1 2 3
025RW032
INTAKE THROTTLE VALVE

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
025RW022
3124
025RW031

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–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)
242RW003
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–15 AUTOMATIC TRANSMISSION (4L30–E)
Chart 4: Poor Shifting In All Gears (All Harsh Or All Soft)
StepActionYe sNo
1Check line pressure. Refer to Line Pressure Test in this section.
Was line pressure normal?
Go to Step 2Go to Step 3
21. Check for these conditions which could affect clutch apply
time:
– Defective band apply solenoid (323).
– Defective servo or/and accumulator piston.
– Excessive clutch piston travel.
2. Check of possible causes of internal leaks:
– Cut or damaged sealing ring(s)
– Damaged sealing gasket(s)
– Check ball missing or out of location in 2nd and 3rd clutch
pistons.
3. Check for caused of burned clutch plates or band.
Was the problem found?
Repair or replace—
3Was the line pressure high?
Go to Step 4
Use Chart 15a:
Possible Causes
of Low Line
Pressure in this
section
4Were DTCs P0560 and P0705 set?
Diagnose those
DTC(s) first
Use Chart 15b:
Possible Causes
of High Line
Pressure in this
section
Chart 5a: Delays In Drive And Reverse
NOTE: A short delay (less than 3 seconds) when first
engaging drive or reverse after allowing vehicle to sit
overnight is normal.
Step
ActionYe sNo
1Check line pressure. Refer to Line Pressure Test in this section.
Was line pressure normal?More than 3
second delay in
drive and reverse
with engine off 1
hour or less.
Teflon seals (508)
on turbine shaft
damaged. Repair
Use Chart 15a:
Possible Causes
of Low Line
Pressure in this
section.
Chart 5b: Delays In Reverse Only
StepActionYe sNo
1Check line pressure. Refer to Line Pressure Test in this section.
Was line pressure normal?
Go to Step 2
Use Chart 15a:
Possible Causes
of Low Line
Pressure in this
section.
2Main case valve body gasket (88) damaged.
– Reverse check ball (85) in valve body (84) missing or out of
location.
– Check for restrictions at valve body transfer plate orifice.
Was the problem found?
Repair—