engine oil OPEL FRONTERA 1998 Workshop Manual

7A–32 AUTOMATIC TRANSMISSION (AW30-40LE)
DTC P0710 (FLASHING CODE 16) OIL TEMPERATURE SENSOR FAILURE (OT2)
D07RY00021Circuit description:
The oil temperature sensor is a thermistor sensor that is
installed in the transmission case and converts
temperature changes into continuous electric signals,
then outputs them to the Transmission Control Module
(TCM). When the ATF temperature is low, the resistance
of the sensor (thermistor) goes up, so that the voltage of
the TCM signal becomes high.
As the ATF is gradually warmed, the resistance of the
sensor goes down and the voltage becomes low. At the
normal operating ATF temperature (80
C/176F) of the
transmission, the voltage of the TCM is about 3.7V.
Fail-safe condition:
The TCM controls fail-safe by detecting oil temperature
sensor failure.
Failure detection:
Short detection
• When the A/D value is detected less than 10
(220
C) for 5 minutes continuously while normal
judgment is not satisfied from ignition on.
Open detection
• After 15 minites passed when the engine revolution
is more than 400 rpm and the selector position
switch is selected on R, D, 2, L range.
• When the change of the A/D value from engine
star t is less than 15 and the minnum A/D value is
more than 1000 (-10
C) from engine star t.
Contents of control:
At failure detection
• Changes shift map to HOT2 map
• Controls as A/T oil temperature 200
C
• Lock-up control inhibit
• Up hill and down hill control inhibit
• Blinks "CHECK TRANS" lamp
• Stores the failure information in failure-memoryAt failure decision
Same as failure detection.
Conditions of turning "CHECK TRANS" off:
Turns "CHECK TRANS" lamp off when judged 0km/h by
output revolution sensor after the normal area of oil
temperature 40
C – 150C is detected for 10 sec
continuously.
Reversion conditions from fail-safe:
Recovers at the same time as the conditions of turning
“CHECK TRANS” lamp off are satisfied.
Test description:
The following numbers correspond to circled numbers on
the diagnostic char t.
(1) Check that the voltage of the oil temperature sensor
varies with ATF temperatures.
(2) Check that the resistance of the oil temperature
sensor varies with ATF temperatures.
Diagnostic aids:
An intermittent may be caused by a poor connection,
rubbed through wire insulation or a wire broken inside
the insulation. Inspect related harness connector for
backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals, poor terminal
to wire connection and damaged harness.

7A–38 AUTOMATIC TRANSMISSION (AW30-40LE)
DTC P0727 (FLASHING CODE 13) ENGINE REVOLUTION SIGNAL FAILURE (NE)
D07RY00019Circuit description:
Engine revolution (rpm) signals are sent from Engine
Control Module (ECM) to the Transmission Control
Module (TCM).
The engine speed sensor is an electromagnetic pulse
pickup type that generates signals when the flywheel
gear revolves (2 pulses at a single revolution of the
flywheel gear).
The TCM converts these sine wave signals into engine
revolution (RPM) signals.
Fail-safe control:
The TCM controls fail-safe by detecting engine revolution
sensor failure.
Failure detection:
• When input revolution is more than 2000 rpm
• When not even 1 pulse is input in the engine
revolution signal during 5 seconds
• Detection inhibit condition: At 4th gear
Contents of control:
At failure detection
• Up hill and down hill control inhibit
• Oil temperature sensor failure detection inhibit
• Blinks "CHECK TRANS" lamp
• Stores the failure information in failure memory.
At failure decision
Same as failure detection
Conditions of turning "CHECK TRANS" lamp off:
Turns "CHECK TRANS" lamp off when judged 0km/h by
speed meter sensor after the engine revolution signal
pulses are input 250 pulses normally.
(however, uses 0 km/h judgment by back-up vehicle
speed at output revolution failure)
Reversion conditions from fail-safe:
Recovers at the same time as the conditions of turning
“CHECK TRANS” lamp off are satisfied.Test description:
The following numbers correspond to circled numbers on
the diagnostic char t.
(1) Engine revolution signals are input from the ECM into
the TCM.
(2) When the engine idling, voltage fluctuates with (AC
intermittent) range of less than 1.4V
9 16V.
Diagnostic aids:
An intermittent may be caused by a poor connection,
rubbed through wire insulation or a wire broken inside
the insulation. Inspect related harness connector for
backed out terminals, improper mating, broken locks,
improperly formed or damaged terminals, poor terminal
to wire connection and damaged harness.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–65
F07RY00004
HYDRAULIC TEST
PREPARATION
1) Warm up the transmission fluid.
2) Remove the transmission case test plug and mount the
hydraulic pressure gauge.
Oil pressure gauge: 5-8840-0093-0
NOTE:
Perform the test at normal operating fluid temperature (50
– 80
C or 122 – 176F).
MEASURE LINE PRESSURE
1) Fully apply the parking brake and chock the four wheels.
2) Start the engine and check idling rpm.
3) Shift into "D" range, step down strongly on the brake pedal
with your left foot and, while manipulating the accelerator
pedal with the right foot, measure the line pressures at the
engine speeds specified in the table.
4) In the same manner, perform the test in "R" range.
EVALUATION
1) If the measured values at all ranges are higher than
specified.
• Pressure control solenoid defective.
• Primary regulator valve defective.
2) If the measured values at all ranges are lower than
specified.
• Primary regulator valve defective.
• Oil pump defective.
• Pressure control solenoid defective.
3) If pressure is low in "D" range only:
• "D" range circuit fluid leakage.
4) If pressure is low in "R" range only:
• "R" range circuit fluid leakage. Engine
speedLine pressure kPa (kg/cm
2/psi)
"D" range "R" range
Idling 358 – 417
(3.6–4.3 / 51–61)588 – 686
(6.0–7.0 / 85–100)
Stall 1,176 – 1,323
(12.0–13.5 / 171–192)1,607 – 1,940
(16.4–19.8 / 233–282)

7A–72 AUTOMATIC TRANSMISSION (AW30-40LE)
TCM STANDARD VOLTAGE
Check circuitTe r m i n a l
Measuring condition Voltage (V)
+-
Throttle position sensorC79-6 C79-28Throttle fully opened (WOT) 3.47
4.56
Throttle fully closed (idling) 0.25
0.45
C79-19 C79-18 Key switch ON 4.75
5.25
Output revolution sensor C79-4 C79-16 Engine idling in gear 0
3
Input revolution sensor C79-5 C79-17 Engine idling 0
3
Speed meter sensor C79-7C78-15
or -19Vehicle speed 10
20 km/h Less than 1.4
about 5
Brake switch C78-18C78-15
or -19Depress brake 7
16
Release brake Less than 1
O/D OFF switch C79-3C78-15
or -19O/D OFF switch ON (O/D OFF) 7
16
O/D OFF switch OFF (O/D ON) Less than 1
Neutral start switch
C79-2C78-15
or -19Selector “P” range 7
16
(P) Selector all ranges except “P” Less than 1
Neutral start switch
C79-1C78-15
or -19Selector “R” range 7
16
(R) Selector all ranges except “R” Less than 1
Neutral start switch
C79-9C78-15
or -19Selector “N” range 7
16
(N) Selector all ranges except “N” Less than 1
Neutral start switch
C79-8C78-15
or -19Selector “D” range 7
16
(D) Selector all ranges except “D” Less than 1
Neutral start switch
C79-21C78-15
or -19Selector “2” range 7
16
(2) Selector all ranges except “2” Less than 1
Neutral start switch
C79-20C78-15
or -19Selector “L” range 7
16
(L) Selector all ranges except “L” Less than 1
Engine revolution signal C79-15C78-15
or -19Engine idling Less than 1.4
9 16
Diagnosis terminal C79-24C78-15
or -19Self-diagnosis ON
0
1.5
Power pattern switch C79-23C78-15
or -19Power pattern switch OFF (NORMAL) 8
16
Power pattern switch ON (POWER) Less than 1.4
Winter select switch C79-13C78-15
or -19Switch OFF 8
16
Switch ON Less than 1.4
Electrical source (Battery) C78-13C78-15
or -19—
9
16
Electrical source (Ignition) C78-20C78-15
or -19Key switch ON
9
16
Oil temperature warning lamp C79-11C78-15
or -19Oil temperature warning lamp ON Less than 1
Oil temperature warning lamp OFF 8
16
“CHECK TRANS lamp” C79-10C78-15
or -19“CHECK TRANS” lamp ON Less than 1
“CHECK TRANS” lamp OFF 8
16
Power lamp C79-22C78-15
or -19Power lamp ON Less than 1
Powe r l a m p O F F 8
16

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–75
ON-VEHICLE SERVICE
242RX00001
TRANSIMISSION FLUID LEVEL AND
CONDITION
Park vehicle on level ground and set parking brake.
With the engine idling, move the shift lever through all
positions from "P" to "L", then return to position "P".
Check to see If the level of fluid comes to "HOT" range
of about 80
C (176F) on the dipstick gauge.
If the level of fluid is too low, replenish to bring it to
maximum level in "HOT" range.
Inspection of fluid condition
If the ATF is black or smells burnt, replace it.
ATF REPLACEMENT
NOTE:
Do not overfill.
1) Remove the drain plug from oil pan and drain the
fluid.
2) Reinstall the drain plug securely.
3) With the engine OFF, add new fluid through the filler
tube.
4) Star t the engine and shift the selector into all
position from "P" through "L", and then shift into "P".
5) With the engine idling, check the fluid level. Add fluid
up to the "COLD" level on the dipstick.
6) The ATF level must be checked again for correct
level with the "HOT" level.
NOTE:
To prevent fluid leaks, the drain plug gasket must be
replaced each time this plug is removed.
Tr a n s m i s s i o n
Drain and refill 5.2 L
Dry fill 8.7 L
Fluid BESCO ATF III

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–81
256RW014
256RW015
INSTALLATION
To install, follow the removal steps in the reverse order, noting
the following points;
Adjustment of select lever and control rod
1) Place the vehicle on a level surface.
NOTE:
If the vehicle is not on a level surface, the shift select cable
set position will vary with the movement of the engine. To
prevent possible misadjustment of the cable, the vehicle
must be placed on a level surface.
2) Install the shift control rod (1) to the transfmission select
lever (2), and then place the lever in the "N" position.
3) Set select lever in the "N" position.
4) Push select lever forward and secure it (using a rubber
band (3), etc.) so that pin comes into contact with the wall
of detent plate.
5) Install the shift control rod (1) to the selector lever arm (4).
NOTE:
Do not apply to threaded portions.
6) After adjustment, operate select lever on a trial basis to
makes sure of its smooth operation and no abnormal
indication in each position.
Adjustment of shift lock cable
1) Set ignition key in "LOCK" position and selector lever in "P"
position.
2) Adjust cable screw cap on selector lever side to provide a
gap (slack for cable) of 1–2mm between rod on steering
lock side and stopper.
Adjust cap as follows:
a. Pull screw cap (1) in arrow direction to put off slack of
inner cable.
b. With cable kept as (a), adjust gap between nut (2) and
bracket to 5mm (0.2in).
c. Lock inner cable by tur ning nut (3) while holding nut (2) in
place.
NOTE:
Clean the rod threads and do not apply oil to the threaded
portions.Nꞏm(kgꞏm / lbꞏft)
Nut torque 32 (3.3/24)
Nꞏm(kgꞏcm / lbꞏin)
Lock nut torque 3.7 (38/33)

7A–86 AUTOMATIC TRANSMISSION (AW30-40LE)
TRANSMISSION REMOVAL AND INSTALLATION
240RY00038
Removal Steps
1. Transfer protector
2. Rear sound cover
3. Front sound cover
4. Rear propeller shaft
5. Front propeller shaft
6. Exhaust pipe
7. Harness connector
8. Front console, selector lever assembly, and
transfer control lever
9. Transfer case assembly
10. ATF cooler pipe and clamp11. Under cover and flex plate-torque conver ter
bolt
12. Rear mounting nut
13. 3rd crossmember
14. Oil level gauge and tube
15. Starter
16. Engine-transmission bolt
17. Transmission assembly
Installation steps
To install, follow the removal steps in reverse order.

AUTOMATIC TRANSMISSION (AW30-40LE) 7A–87
253RY00001
REMOVAL
Preparation
:
• Remove engine hood.
• Disconnect negative (–) battery cable.
1. Transfer protector
2. Rear sound cover
3. Front sound cover
4. Rear propeller shaft
5. Front propeller shaft
NOTE:
Apply alignment marks on the flange at both front and rear
sides.
6. Exhaust pipe
• Remove the 2nd front exhaust pipe from the 1st front
exhaust pipe and exhaust silencer.
7. Transmission harness connector
• Disconnect the harness connectors from the
transmission.
8. Front console, selector lever assembly, and transfer
control lever
• Disconnect the transfer control lever knob.
• Remove the front console.
• Disconnect the harness connector.
• Remove the selector lever assembly.
• Disconnect the shift control rod from the transmission.
9. Transfer case assembly
• Disconnect the breather hose from the transfer case.
• Remove the transfer case assembly from the
transmission.
10. ATF cooler pipe and clamp
• Disconnect two ATF cooler pipes from A/T side.
• Remove oil pipe clamp from torque converter housing
side.
• Loosen oil pipe clamp bolt at engine mount side.

7A–88 AUTOMATIC TRANSMISSION (AW30-40LE)
240RY00026
022RY00001
11. Under cover and flex plate-torque converter bolt
• Remove the under cover.
• Turn the crankshaft to gain access to each bolt.
Remove the six torque cover ter fixing bolts.
NOTE:
New fixing bolts should be replaced for reassembly.
12. Rear mounting nut
• Support transmission with a jack.
• Remove two rear mounting nuts from the 3rd
crossmember.
13. 3rd crossmember
14. Oil level gauge and tube
15. Starter
• Remove the mounting bolts, and pull the star ter toward
the front of the vehicle.
Lay the star ter alongside the engine.
16. Engine-transmission bolt
• Remove engine-transmission fixing bolts.
• Disconnect the breather hose from the breather hose 3
way (W/TOD) or 2 way (WO/TOD).
17. Transmission assembly
NOTE:
Keep the oil pan positioned down.
Be careful not to let the torque converter slide out.

7A1–6
TRANSMISSION CONTROL SYSTEM (4L30–E)
Shift Control
The transmission gear is shifted according to the shift
pattern selected by the driver. In shifting gears, the gear
ratio is controlled by the ON/ OFF signal using the shift
solenoid A and the shift solenoid B.
Band Apply Control
The band apply is controlled when in the 3–2 downshift
(engine overrun prevention) and the garage shift (shock
control).
The band apply solenoid is controlled by the signal from
the Pulse Width Modulation (PWM) to regulate the flow of
the oil.
Torque Converter Clutch Control
The clutch ON/OFF is controlled by moving the converter
clutch valve through shifting Torque Converter Clutch
(TCC) solenoid using the ON/OFF signal.
Line Pressure Control
The throttle signal allows the current signal to be sent to
the force motor. After receiving the current signal, the
force motor activates the pressure regulator valve to
regulate the line pressure.
On–Board Diagnostic System
Several malfunction displays can be stored in the
Powertrain Control Module (PCM) memory, and read out
of it afterward.The serial data lines, which are required for the testing of
the final assembly and the coupling to other electronic
modules, can be regulated by this function.
Fail Safe Mechanism
If there is a problem in the transmission system, the PCM
will go into a “backup” mode.
The vehicle can still be driven, but the driver must use the
select lever to shift gears.
Torque Management Control
The transmission control side sends the absolute spark
advance signal to the engine control side while the
transmission is being shifted. This controls the engine
spark timing in compliance with the vehicle running
condition to reduce the shocks caused by the change of
speed.
ATF Warning Control
The oil temperature sensor detects the ATF oil
temperature to control the oil temperature warning, TCC,
and the winter mode.
ABS Control (If equipped)
When the select lever is at “L” or “R” range, a signal is sent
to the ABS controller as one of the ABS control
conditions.