2.2 OPEL FRONTERA 1998 Repair Manual

ENGINE MECHANICAL 6A – 93
11. Use the special tool to install the crankshaft front oil
seal to timing gear case.
Front Oil Seal Installer: 5-8840-2061-0
1) Check fit-of the oil seal and gear case cover at
the front end.
Standard: 0.5 – 2.5 mm (0.0197 – 0.0984 in)
NOTE: Apply engine oil to oil seal lip before installation
of the seal.
12. Install the oil pan assembly to original position and
tighten to specified torque.
Torque: 22 Nꞏm (2.2 kgꞏm/15.9 lb ft)
13. Crankshaft Rear Oil Seal
1) Tighten the adapter to the crankshaft rear end
with 2 bolts.
2) Insert the oil seal into 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) With the seal pressed in, check the dimension of
the oil seal outside end and crankshaft end.
Standard Dimension = 12.5 ± 0.3 mm
Oil Seal Installer: 5-8840-2359-014. Cylinder Block Rear Plate (A/T Model)
1) Tighten the cylinder block rear plate fixing bolts
to the specified torque.
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
15. Flywheel Housing (M/T Model)
1) Install flywheel housing aligned with the dowel
pin on the cylinder block.
2) Tighten the flywheel housing fixing bolts to the
specified torque.
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
16. Flywheel
1) Refer to “Crankshaft” in this manual.
17. Cylinder Head Assembly
1) Refer to “Cylinder Head” in this manual.
015RW074
12.5 + 0.3–
012RW067

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

7A–50
AUTOMATIC TRANSMISSION (4L30–E)
36. Separate second (40) and third clutch (41)
assemblies.
37. Remove thrust washer (42).
38. Remove reverse clutch plates (43 and 44) and
reverse clutch pressure plate (45).
39. Remove bearing (46) and washer (47).
40. Remove planetary carrier assembly (48).
41. Remove thrust bearing (49).
42. Remove reaction sun gear (50)
43. Remove needle bearing (51).
44. Remove brake drum (52).
45. Remove brake band (53).
46. Remove thrust bearing (54).
242RS003
47. Rotate case to horizontal position, valve body side
facing up.
Remove spring pin (55), using cutting pliers, then
remove parking lock and selector lever assembly
(56).NOTE: Insert wire in the center of the spring pin to
prevent it from collapsing during removal. Be aware of pin
height. Protect machined face of main case.
48. Remove parking lock and range selector lever 17 mm
nut (57).
49. Remove parking lock and range selector lever (56),
and actuator assembly.
50. Remove selector shaft (58).
NOTE: Inspect the shaft for burrs before removing to
prevent damaging seal. If necessary, remove burrs by
lightly sanding with an oilstone.
249RS004
Reassembly
1. Inspect selector shaft seal, and replace it if
necessary.
NOTE: Use a seal installer when replacing the seal.
Install selector shaft.
NOTE: Spring pin groove must be positioned inside the
case.
2. Install spring pin. Be sure the selector shaft can move
freely. Do not push the pin flush with the case surface.
Leave enough height for removal.
3. Install actuator assembly (1).
4. Install parking lock and range selector lever (2) and
new 17 mm nut. Tighten the nut to the specified
torque.
To r q u e : 2 2 N
m (2.2 kgꞏm/16 lb ft)

7A–53 AUTOMATIC TRANSMISSION (4L30–E)
22. Second clutch end play measurement
1. Install the 5–8840–2262–0 (J–23085–A)
Selective washer gauging tool (with spacer ring)
on the case flange and against the intermediate
shaft.
2. Position the inner shaft of the gauging tool against
the thrust surface of the second clutch hub.
3. Tighten thumb screw. Remove the tool.
4. Fit the spacer ring on the inner shaft of the tool.
5. Measure the gap, and select the appropriate
washer as shown in the chart.
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
RESULT IN FINAL END–PLAY FROM 0.36 mm TO
0.79 mm (0.014 in TO 0.031 in)
247RY00048
247RW004
23. Inspect fourth clutch piston seals and replace if
necessary.
Lubricate 5–8840–2267–0 (J–38554) fourth clutch
piston fitter and install it on fourth clutch piston (19).
Install fourth clutch piston (19) in adapter case (20).
Remove fitter.
252RW006

7A–55 AUTOMATIC TRANSMISSION (4L30–E)
33. Install fourth clutch retainer (31) with the notch facing
up and positioned towards valve body surface.
252RW004
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
RESULT IN FINAL END–PLAY FROM 0.1 mm TO
0.8 mm (0.004 in TO 0.03 in)
252RW008
252RW009
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–176 AUTOMATIC TRANSMISSION (AW30-40LE)
247RY00002
246RY00022
247RY00043
8. Snap ring
Set special tool as shown, and compress the return spring
with special tool.
Spring compressor : 5–8840–0254–0 (J–25048)
Install the snap ring with snap ring pliers. Be sure the end
gap of the snap ring is not aligned with the spring retainer
claw.
Check first and reverse brake piston
Make sure the first and reverse brake piston moves
smoothly when applying and releasing the compressed air
into the transmission case.
9. Thrust bearing and race
Coat the assembled bearing and race with petroleum jelly.
Install the assembled bearing and race facing the bearing
side upward.
Assembled bearing and race
diameter. (Reference) mm (in.)
Inside diameter 39.2 (1.543)
Outside diameter 57.7 (2.272)

7A–186 AUTOMATIC TRANSMISSION (AW30-40LE)
247RY00008
247RY00009
247RY00010
246RY00003
Important operations
1. Bearing
Coat the assembled bearing and race with petroleum jelly
and install it onto the case.
2. Rear planetary gear, second brake drum and output
shaft
Align the teeth of the second brake drum, flanges, discs
and plates as shown in the figure.
Align the splines of the transmission case and the
assembled rear planetary gear, second brake drum and
output shaft, indicated by A in the figure at left.
3. Snap ring
Using snap ring pliers, install the snap ring. Assemble bearing and race (reference) mm (in.)
Bearing and race Diameter
Inside 39.2 (1.543)
Outside 57.7 (2.272)

7A–198 AUTOMATIC TRANSMISSION (AW30-40LE)
246RY00001
252RY00014
241RY00003
Install the (stepped ring) flange with the flat side of the
flange facing the disc.
Install the snap ring.
32.Race
Coat the race with petroleum jelly and install it onto the oil
pump.
33.Oil pump
Coat the O–ring with ATF and install it around the pump
body.
Place the oil pump through the input shaft, and align the
bolt holes of the pump body with the transmission case.
Hold the input shaft, and lightly press the oil pump body to
slide the oil seal rings on the stator shaft through the direct
clutch drum.
NOTE:
Do not push on the oil pump strongly or the oil seal ring
will stick to the direct clutch drum.
Install the seven bolts.
Check input shaft rotation
Make sure the input shaft rotates smoothly. Race diameter (Reference) mm (in.)
Inside Outside
Race 28.1 (1.106) 47.3 (1.862)
Nꞏm(kgꞏm / lbꞏft)
Torque 22 (2.2/16)

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–201
240RY00015
240RY00029
240RY00010
240RY00016
3. Check valve, spring
Install new check valve and spring.mm (in.)
Piston Outer diameter Height
B–2 36.8 (1.449) 62.5 (2.461)
C–2 36.8 (1.449) 56.6 (2.228)
B–0 31.8 (1.252) 52.0 (2.047)
C–0 29.8 (1.173) 44.0 (1.732)
Spring Free length Outer diameter
(1) B–2 75.8 (2.984) 20.1 (0.791)
(2) C–2 (Inner) 42.1 (1.658) 14.7 (0.579)
(3) C–2 (Outer) 64.0 (2.520) 20.2 (0.795)
(4) B–0 63.6 (2.504) 16.0 (0.630)
(5) C–0(Outer) 74.6 (2.937) 20.9 (0.823)
(6) C–0(Inner) 46.0 (1.811) 14.0 (0.551)