Opel Frontera UBS. Service manual — part 1416
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
3
1
2
4
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 N·m (2.0 kg·m / 14.5 lb ft) for bolt
Torque: 20 N·m (2.0 kg·m / 14.5 lb ft) for nut
2. Install fuel pipe.
Torque: 4 N·m (0.4 kg·m / 2.9 lb ft) for M16 nut
(Apply engine oil)
Torque: 13 N·m (1.3 kg·m / 9.4 lb ft) for M10 cap nut
Torque: 14 N·m (1.4 kg·m / 10 lb ft) for M10
(Apply engine oil)
3. Install two way check valve.
Torque: 20 N·m (2.0 kg·m / 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 N·m (3.0 kg·m / 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
6J – 12 INDUCTION
IHI SERVICE NETWORK
For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger Service
Facility.
HEADQUARTERS
ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD. (IHI)
General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN
TEL: 81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430
CHINA
IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, People’s R epublic of CHINA
TEL: 86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX: 210343 IHIPK CN
TAIWAN
IHI TAIPEI OFFICE
Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL: 886-(2)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
TLX: 11320 IHICO
THAILAND
IHI BANGKOK OFFICE
8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND
TEL: 66-(2)-236-3490, 7356, 9099
FAX: 66-(2)-236-7340
TLX: 82375 IHICO TH
MALAYSIA
IHI KUALA LUMPUR OFFICE
Letter Box No. 52, 22nd Floor, UBN Tower,
10 Jin. P. Ramlee 50250 Kuala Lumpur, MALAYSIA
TEL: 60-(3)-232-1255, 1271
FAX: 60-(3)-232-1418
TLX: IHI KLMA 20257
INDONESIA
IHI JAKARTA OFFICE
9th Floor, Skyline Building JI. M.H. Thamrin, No. 9, Jakarta, INDONESIA
TEL: 62-(21)-32-2147, 390-2211
FAX: 62-(21)-32-3273
TLX: 44175 IHIJKT
7A–1
AUTOMATIC TRANSMISSION (4L30–E)
TRANSMISSION
AUTOMATIC TRANSMISSION (4L30–E)
CONTENTS
Service Precaution
7A–3
. . . . . . . . . . . . . . . . . . . . . .
Construction
7A–3
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Range Reference Chart
7A–4
. . . . . . . . . . . . . . . . . .
Normal Operation Of 2000 4L30–E
Transmission
7A–5
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis
7A–5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Information
7A–5
. . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis Procedure
7A–8
. . . . . . . . . . . . .
Preliminary Inspection Chart
7A–9
. . . . . . . . . . . . . .
Checking Transmission Fluid Level and
Condition
7A–10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Driving
7A–11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical / Hydraulic Diagnosis Check Trans
Indicator Chart
7A–12
. . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical / Hydraulic Diagnosis
Symptoms Index
7A–13
. . . . . . . . . . . . . . . . . . . . . . . .
Stall Test
7A–23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Test
7A–23
. . . . . . . . . . . . . . . . . . . . . .
Shift Speed Chart (V6 3.2L 6VD1 Model)
7A–24
. . .
Shift Speed Chart (V6 3.5L 6VE1 Model)
7A–26
. .
Lockup Speed Chart (V6 3.2L 6VD1 Model)
7A–28
Lockup Speed Chart (V6 3.5L 6VE1 Model)
7A–28
Changing Transmission Fluid
7A–29
. . . . . . . . . . . . .
Selector Lever
7A–29
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection
7A–29
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
7A–30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–30
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Switch
7A–31
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
7A–31
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–31
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (With Transfer Case)
7A–33
. . . . . . . .
Transmission And Associated Parts
7A–33
. . . . . .
Removal
7A–33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–35
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid (Main Case Valve Body)
7A–39
. . . . . . . . .
Removal
7A–39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–39
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid (Adapter Case Valve Body)
7A–40
. . . . . . .
Removal
7A–40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–40
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Main Case)
7A–41
. . . . . . . .
Removal
7A–41
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–41
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Adapter Case)
7A–43
. . . . . .
Removal
7A–43
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–43
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM)
7A–43
. . . . . . . . .
Removal
7A–43
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–43
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Sensor (Extension Housing)
7A–44
. . . . . . . .
Removal
7A–44
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–44
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Temperature Sensor
(Adapter Case)
7A–44
. . . . . . . . . . . . . . . . . . . . . . . . .
Removal
7A–44
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–45
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Oil Seal (Converter Housing)
7A–45
. . . . . . . .
Removal
7A–45
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–45
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal (Extension Housing)
7A–46
. . . . . . . . .
Removal
7A–46
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
7A–46
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (4L30–E)
7A–46
. . . . . . . . . . . . . . . . . .
Disassembly
7A–46
. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly
7A–50
. . . . . . . . . . . . . . . . . . . . . . . . . .
Converter Housing And Oil Pump Assembly
7A–60
Disassembled View
7A–60
. . . . . . . . . . . . . . . . . . . .
Disassembly
7A–60
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair
7A–60
. . . . . . . . . . . . . . . . . .
Reassembly
7A–60
. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump
7A–61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View
7A–61
. . . . . . . . . . . . . . . . . . . .
Disassembly
7A–61
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair
7A–61
. . . . . . . . . . . . . . . . . .
Reassembly
7A–61
. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Case Valve Body
7A–62
. . . . . . . . . . . . . . . . . . .
Disassembled View
7A–62
. . . . . . . . . . . . . . . . . . . .
Disassembly
7A–62
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair
7A–63
. . . . . . . . . . . . . . . . . .
Reassembly
7A–63
. . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter Case Valve Body
7A–64
. . . . . . . . . . . . . . . .
Disassembled View
7A–64
. . . . . . . . . . . . . . . . . . . .
Disassembly
7A–64
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair
7A–64
. . . . . . . . . . . . . . . . . .
Reassembly
7A–64
. . . . . . . . . . . . . . . . . . . . . . . . . .
Third Clutch And Sprag Unit
7A–65
. . . . . . . . . . . . . .
Disassembled View
7A–65
. . . . . . . . . . . . . . . . . . . .
Disassembly
7A–65
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair
7A–66
. . . . . . . . . . . . . . . . . .
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