oil filter OPEL FRONTERA 1998 Repair Manual

7A–36
AUTOMATIC TRANSMISSION (4L30–E)
Solenoid (Main Case Valve Body)
Removal
1. Raise the vehicle and support it on jack stands.
2. Disconnect battery ground cable.
3. Remove transfer and exhaust protectors.
4. Drain fluid.
5. Remove exhaust pipe and disconnect oxygen sensor
connector.
6. Support transfer case with a jack and remove third
crossmember.
7. Remove sixteen 10 mm screws, main case oil pan,
magnet, and gasket.
8. Remove three 13 mm screws, oil filter.
9. Disconnect wiring harness from band control
solenoid and shift solenoids. Pull only on connectors,
not on wiring harness.
10. Remove spring pin for shift solenoid A, shift solenoid
B, and band control solenoid respectively, using
suitable pliers taking care not to damage solenoids.
210RW010
244RW003
11. Remove shift solenoid A, shift solenoid B, band
control solenoid, and gaskets from main case valve
body. Do not pull on wiring harness. Remove
solenoids by grasping the metal tip.
Installation
1. Install shift solenoid A, shift solenoid B, band control
solenoid with new gaskets to main case valve body
respectively.
2. Carefully install spring pin with hammer to avoid
damage to valve body, etc.
243RW004
3. Connect wiring harness to solenoids.
4. Install oil filter with a new gasket and the three 13 mm
screws. Tighten the screws to the specified torque.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
5. Install magnet, main case oil pan with new gasket,
sixteen 10 mm screws. Tighten the screws to the
specified torque.
To r q u e : 11 N
m (1.1 kgꞏm/96 lb in)
6. Install third crossmember and rear mount nuts.
Tighten the nuts and bolts to the specified torque.
Third crossmember bolt: 50 N
m
(5.1 kgꞏm/37 lb ft)
Rear mount nut: 50 N
m (5.1 kgꞏm/37 lb ft)
7. Install exhaust pipe and connect oxygen sensor
connector. Tighten the bolts to the specified torque.
Exhaust pipe flange bolt torque:
43 N
m(4.4kgꞏm/32lbft)
8. Install the transfer and exhaust protectors. Tighten
the bolts to the specified torque.
Torque: 37 N
m (3.8 kgꞏm/27 lb ft)
9. Fill transmission through the overfill screw hole of oil
pan, using ATF DEXRON
–III. Refer to Changing
Transmission Fluid in this section.
10. Connect the battery ground cable.

7A–38
AUTOMATIC TRANSMISSION (4L30–E)
Valve Body Assembly (Main Case)
Removal
1. Raise the vehicle and support it on jack stands.
2. Disconnect battery ground cable.
3. Remove transfer and exhaust protectors.
4. Drain fluid.
5. Remove exhaust pipe and disconnect oxygen sensor
connector.
6. Support transfer case with a jack and remove third
crossmember.
7. Remove sixteen 10 mm screws, main case oil pan,
magnet and gasket.
8. Remove three 13 mm oil filter fixing screws, then
remove oil filter.
9. Remove two 13 mm manual detent fixing screws,
then remove roller and spring assembly.
10. Disconnect wiring harness from band control
solenoid and shift solenoids. Pull only on connectors,
not on wiring harness.
11. Remove four 13 mm servo cover fixing screws, then
remove servo cover and gasket.
12. Remove seven 13 mm valve body fixing screws.
Disconnect the ground wire from the main case
valve body.
13. Remove main case valve body with manual valve link
and transfer plate. Note the position of the link (long
end into valve, short end into range selector lever).
14. Remove transfer plate gasket from main case.
15. Remove two check balls from main case.
Installation
1. Install two check balls to main case.
244RW002
2. Inspect electrical 4 pin connector and seal of main
case. Replace if necessary.3. Use two 5–8840–0022–0 (J–25025–B) guide pin to
install main case.
Install valve body assembly and manual valve link.
NOTE: Valve must be extended as the short end of
manual valve link is connected to the range selector lever.
Long end of link goes into valve.
4. Install seven 13 mm screws, and tighten them to the
specified torque.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
243RS008
5. Install 8.5 mm connector of ground wire the head of
this valve body bolt and reinstall it. Tighten the bolt to
the specified torque.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
244RW001
6. Remove two guide pins from main case.
7. Install servo cover gasket, cover, and four 13 mm
screws. Tighten the screws to the specified torque.
To r q u e : 2 5 N
m (2.6 kgꞏm/18 lb ft)

7A–39 AUTOMATIC TRANSMISSION (4L30–E)
8. Connect wiring harness to band control and shift
solenoids.
9. Install roller and spring assembly to manual detent.
Install two 13 mm screws, and tighten them to the
specified torque.
Torque: 20 N
m (2.0 kgꞏm/15 lb ft)
10. Install oil filter and three 13 mm screws. Tighten the
screws to the specified torque.
Torque : 20 N
m (2.0 kgꞏm/15 lb ft)
11. Install oil pan gasket, magnet, oil pan and sixteen 10
mm screws. Tighten the screws to the specified
torque.
Torque: 11 N
m (1.1 kgꞏm/96 lb in)
12. Install third crossmember and rear mount. Tighten the
bolts and nuts to the specified torque.
Torque
Third crossmember bolt:
50 N
m (5.1 kgꞏm/37 lb ft)
Rear mount nut: 50 N
m(5.1kgꞏm/37lbft)
13. Install exhaust pipe and connect oxygen sensor
connector. Tighten the bolts to the specified torque.
Exhaust pipe flange bolt torque:
43 N
m (4.4 kgꞏm/32 lb ft)
14. Install transfer and exhaust protectors. Tighten the
bolts to the specified torque.
Torque: 37 N
m (3.8 kgꞏm/27 lb ft)
15. Fill transmission through overfill screw hole of oil pan,
using ATF DEXRON
–III, refer to Changing
Transmission Fluid in this section.
16. Connect battery ground cable.

7A–44
AUTOMATIC TRANSMISSION (4L30–E)
6. Remove seven 13mm adapter case valve body (6)
fixing screws, adapter case valve body assembly,
transfer plate, and two gaskets.
Remove wiring harness and 5 pin connector.
7. Remove sixteen 10mm main case oil pan (7) fixing
screws, main oil pan, magnet, and gasket.
8. Remove three 13mm oil filter (8) fixing screws and oil
filter.
9. Remove two 13mm manual detent (9) fixing screws,
roller and spring, and manual detent.
10. Disconnect wiring harness assembly (10) from band
apply solenoid, shift solenoids, and main case 4 pin
connector.
Pull on connectors only, not on wiring harness.11. Remove four 13mm servo cover (11) fixing screws,
servo cover, and gasket.
12. Remove seven 13mm valve body screws and ground
wire from main case.
Remove wiring harness assembly (5) from the
adapter case side.
Remove main valve body assembly (12) with
manual valve link and transfer plate. Note the
position of the link (long end into valve, short end
into range selector lever).
Remove 4 pin connector.
Remove gasket transfer plate from main case.
13. Remove two check balls (13) from main case.
240RW022
14. Turn transmission to vertical position to drain fluid.
Return back to horizontal position when drained.
Install 5–8840–0501–0 (J–23075) servo piston
spring compressor with offset to the rear of case.
Compress servo piston assembly.
Remove servo piston retaining ring (14).
Slowly release servo piston assembly (15).
Remove tool.
15. Remove servo piston assembly (15), return spring
(16), and servo apply rod (17).

7A–55 AUTOMATIC TRANSMISSION (4L30–E)
242RW008
46. Install two check balls (44).
244RW002
47. Inspect main case electrical connector and seal,
replace if necessary.
Install electrical 4 pin connector/main case and
wiring harness.
48. Install two 5–8840–0022–0 (J–25025–B) guide pins
into main case.
Install main case valve body complete assembly
(45) and manual valve link.NOTE: Valve must be extended as the short end of
manual valve link is connected to the range selector lever.
Long end of link goes into valve.
Install seven 13 mm screws.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
Pass ground wire of adapter case wiring harness
assembly through the hole joining adapter fluid area
and main case fluid area.
Assemble 8.5 mm connector of ground wire under
the head of this valve body bolt and reinstall it.
Remove two guide pins.
244RW001
49. Install servo cover gasket, cover (46) and four 13 mm
screws.
To r q u e : 2 5 N
m (2.6 kgꞏm/18 lb ft)
50. Connect wiring harness (47) to band control, shift
solenoids, and main case 4 pin connector.
51. Install manual detent roller and spring assembly (48)
with clip.
Install two 13 mm screws.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
52. Install oil filter (49), and three 13 mm screws.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
53. Install oil pan gasket, magnet, main oil pan (50), and
sixteen 10 mm screws.
To r q u e : 11 N
m (1.1 kgꞏm/96 lb in)
54. Inspect adapter case electrical connector and seal.
Replace if necessary.
Install electrical five pin connector and harness
assembly (52) in bottom of adapter case.
55. Install gasket, transfer plate, and gasket.
Install adapter case valve body (51) and seven 13
mm screws.
Torque: 20 N
m (2.0 kgꞏm/15 lb ft)

7A–85 AUTOMATIC TRANSMISSION (4L30–E)
(38) Seal, O–Ring
(39) Reservoir
(42) Gasket, Extension Case
(43) Extension Assembly
(44) Seal, O–Ring/Speed Sensor
(45) Sensor Assembly, Speed
(46) Screw, Speed Sensor
(50) Seal, Extension Assembly
(52) Screw, Extension/Main Case
(53) Spring, Parking Pawl Lock
(54) Pawl, Parking Lock
(55) Connector, Electrical/Main Case
(56) Actuator Assembly, Parking Lock
(57) Nut, Parking Lock Lever
(58) Link, Manual Valve
(59) Pin, Spring
(60) Lever, Parking Lock and Range Selector
(61) Shaft, Selector
(62) Seal, Selector Shaft
(63) Mode Switch Assembly
(64) Screw and Conical Washer Assembly
(65) Shield, Mode Switch
(67) Pan, Bottom/Adapter Case
(68) Gasket, Bottom Pan/Adapter Case
(69) Harness Assembly, Adapter Case
(70) Screw, Valve Body
(71) Valve Body Assembly, Adapter Case
(72) Gasket, Adapter Valve Body
(73) Plate, Adapter Valve Body/Transfer
(74) Pan, Bottom/Main Case(75) Gasket, Bottom Pan/Main Case
(76) Gasket, Oil Drain or Overfill Screw
(77) Screw, Oil Drain or Overfill
(78) Magnet, Chip Collector
(79) Filter Oil
(80) Harness Assembly, Main Case
(82) Roller and Spring Assembly, Manual Detent
(84) Valve Body Assembly, Main Case
(85) Ball, Check
(86) Gasket, Main V.B./Transfer Plate
(87) Plate, Main V.B./Transfer
(88) Gasket, Transfer/Main Case
(89) Screw, Transfer Plate on V.B.
(90) Screw, Servo Cover
(91) Cover, Servo Piston
(92) Gasket, Cover/Servo Piston
(93) Ring, Retaining Servo Piston
(94) Clip, Servo Piston
(95) Nut, Servo Screw
(96) Screw, Servo Piston
(97) Piston, Servo
(98) Seal, Ring/Servo Piston
(99) Spring, Cushion/Servo Piston
(100) Seat, Cushion Spring
(101) Sleeve, Servo Piston Adjust
(102) Rod, Apply/Servo Piston
(103) Spring, Return/Servo Piston
(104) Gasket, Adapter Case/Transfer Plate
(105) Powertrain Control Module
(106) Servo Piston Assembly

6A–3
ENGINE MECHANICAL
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick–up unit.
The 12–volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die–cast casting
for 75
V–type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent–roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V–type design. The ports are cross–flow
type.
Va l v e Tr a i n
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast–iron. Pins and
journals are graded for correct size selection for their
bearing.
Engine Lubrication
The oil discharged by a trochoid–type oil pump driven by
the crankshaft is fed through full–flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.

6A–4
ENGINE MECHANICAL
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Condition
Possible causeCorrection
Headlights go out or dim
considerably
Battery run down or under chargedRecharge or replace battery
considerablyTerminals poorly connectedClean battery posts and terminals
and connect properly
Starting motor coil circuit shortedOverhaul or replace
Starting motor defectiveOverhaul or replace
2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect an igniton coil from any spark plug. Connect
the spark plug tester 5–8840–0607–0, start the engine,
a n d c h e c k i f a s p a r k i s g e n e r a t e d in t h e s p a r k p l u g t e s t e r.
Before starting the engine, make sure that the spark plugtester is properly grounded. To avoid electrical shock, do
not touch the part where insulation of the igniton coil is
broken while the engine is running.
Condition
Possible causeCorrection
Spark jumps across gapSpark plug defectiveClean, adjust spark gap or replace
Ignition timing incorrectRefer to Ignition System
Fuel not reaching fuel injector(s) or
engineRefer to item 3 (Trouble in fuel
system)
Valve timing incorrectAdjust
Engine lacks compressionRefer to item 4 (Engine lacks
compression)
No sparking takes placeIgnition coil disconnected or brokenConnect properly or replace
Electronic Ignition System with
moduleReplace
Poor connections in engine harnessCorrect
Powertrain Control Module cable
disconnected or defectiveCorrect or replace
3. Trouble In Fuel System
Condition
Possible causeCorrection
Starting motor turns over and spark
occurs but engine does not start
Fuel tank emptyFill
occurs but engine does not start.Water in fuel systemClean
Fuel filter cloggedReplace filter
Fuel pipe cloggedClean or replace
Fuel pump defectiveReplace
Fuel pump circuit openCorrect or replace
Evaporative Emission Control
System circuit cloggedCorrect or replace
Multiport Fuel Injection System faultyRefer to “Electronic Fuel Injection”
section

6A–7
ENGINE MECHANICAL
Condition CorrectionPossible cause
OthersEngine lacks compressionRefer to “Hard Start”
Valve incorrectly seatedLap valve
Air Cleaner Filter cloggedReplace filter element
Valve timing incorrectReadjust
Idle air control valve brokenReplace
Fast idle solenoid defectiveReplace
Positive Crankcase Ventilation valve
defective or cloggedReplace
Rough Engine Running
ConditionPossible causeCorrection
Engine misfires periodicallyIgnition coil layer shortedReplace
Spark plugs foulingClean or install hotter type plug
Spark plug(s) insulator nose leakingReplace
Fuel injector(s) defectiveReplace
Powertrain control module faultyReplace
Engine knocks periodicallySpark plugs running too hotInstall colder type spark plugs
Powertrain control module faultyReplace
Engine lacks powerSpark plugs fouledClean
Fuel injectors defectiveReplace
Mass Airflow Sensor or Intake
Airflow Sensor circuit defectiveCorrect or replace
Manifold Absolute Pressure (MAP)
Sensor or Manifold Absolute
Pressure Sensor circuit defectiveCorrect or replace
Engine Coolant Temperature Sensor
or Engine Coolant Temperature
Sensor circuit defectiveCorrect or replace
Powertrain Control Module faultyReplace
Intake Air Temperature Sensor or
Intake Air Temperature Sensor
circuit defectiveCorrect or replace
Throttle Position Sensor or Throttle
Position Sensor circuit defectiveCorrect or replace
Knock Sensor or Knock Sensor
circuits defectiveCorrect or replace
Knock Sensor Module or Knock
Sensor Module circuits defectiveCorrect or replace

6A–10
ENGINE MECHANICAL
Engine Lacks Power
ConditionPossible causeCorrection
Trouble in fuel systemFuel Pressure Control Valve not
working normallyReplace
Fuel injector cloggedClean or replace
Fuel pipe cloggedClean
Fuel filter clogged or fouledReplace
Fuel pump drive circuit not working
normallyCorrect or replace
Fuel tank not sufficiently breathing
due to clogged Evaporative
Emission Control System circuitClean or replace
Water in fuel systemClean
Inferior quality fuel in fuel systemUse fuel of specified octane rating
Powertrain Control Module supplied
poor voltageCorrect circuit
Throttle Position Sensor cable
broken or poor connectionsCorrect or replace
Throttle Position Sensor defectiveReplace
Mass Airflow Sensor not working
normallyReplace
Manifold Absolute Pressure Sensor
not working normallyReplace
Intake Air Temperature Sensor not
working normallyReplace
Engine Coolant Temperature Sensor
circuit open or shortedCorrect or replace
Engine Coolant Temperature Sensor
defectiveReplace
Powertrain Control Module defectiveReplace
Trouble in intake or exhaust systemAir Cleaner Filter cloggedReplace filter element
Air duct kinked or flattenedCorrect or replace
Ignition failure————Refer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequateInstall spark plugs of adequate heat
range
Ignition coil defectiveReplace