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Opel Frontera UBS. 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

Legend

(1)

Intake Manifold

(2)

Throttle Valve Assembly

(3)

EGR Valve

(4)

Gasket

025RW022

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

. . . . . . . . . . . . . . . . . .

SECTION

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