OPEL FRONTERA 1998 Workshop Manual

6D3–10STARTING AND CHARGING SYSTEM
Check for continuity between commutator and shaft.
Also, check for continuity between commutator and
armature core,armature core and shaft. Replace
commutator if there is continuity (i.e., internally
grounded).
065RS016Measure runout of armature core and commutator with a
dial gauge. Repair or replace, if it exceeds the limit.
Armature
Standard: 0.05 mm (0.002 in) Max.
Limit: 0.10 mm (0.004 in)
Commutator
Standard: 0.05 mm (0.002 in) Max.
Limit: 0.10 mm (0.004 in)
065RS017
Polish the commutator surface with sandpaper #500 to
#600 if it is rough.
065RW012Measure the depth of insulator in commutator. Repair, if it
is below the limit.
Standard: 0.05 mm to 0.8 mm (0.02 in to 0.03 in)
Limit: 0.2 mm (0.008 in)
065RW013
Legend
(1) Steel Saw
(2) Insulator
(3) Commutator Segments

6D3–11 STARTING AND CHARGING SYSTEM
Brush
Measure the length of brush.
Replace with a new one, if it is below the limit.
Standard: 16 mm (0.63 in)
Limit: 11 mm (0.43 in)
065RW014
Brush Holder
Check for continuity between brush holder (+) (4) and
base (–). Replace, if there is continuity (i.e., insulation is
broken).
065RW015
Magnetic Switch
Check for continuity of shunt coil between terminals S and
M.
Replace, if there is no continuity (i.e., coil is
disconnected).
065RW016
Continuity of Series Coil
Check for continuity between terminals S and M.
Replace, if there is no continuity (i.e., coil is
disconnected).
065RW017

6D3–12STARTING AND CHARGING SYSTEM
Continuity of Contacts
With the plunger faced downward, push down the
magnetic switch. In this state, check for continuity
between terminals B and M. Replace, if there is no
continuity (i.e., contacts are faulty).
065RW018
Pinion
Check if the pinion rotates smoothly in drive direction by
hand, or if it is locked when it is rotated in reverse. If not,
replace the pinion.
065RS025
Yoke Assembly
Check a magnet inside the yoke.
Replace the yoke assembly if it is broken.
065RS026
Ball Bearing
Clamp the inner race of the ball bearing with your finger,
and check for sticking or play when rotating the outer
race.
Replace, if abnormality is found.
065RS027

6D3–13 STARTING AND CHARGING SYSTEM
Measure inner diameter of bushing in the rear cover, and
replace if it exceeds the limit.
Standard: 12.50 mm to 12.527 mm (0.492 in to
0.4932 in)
Limit: 12.60 mm (0.4961 in)
065RS028Measure inner diameter of bushing in the center bracket
(P), and replace if it exceeds the limit.
Standard: 18.01 mm to 18.127 mm (0.7091 in to
0.7137 in)
Limit: 18.15 mm (0.7146 in)
065RS029
Reassembly
To install, follow the removal steps in the reverse order,
noting the following points:
Grease application places
Bushing in rear cover and center bracket
Gears in reduction gear
Shift lever operating portion
Sliding portion of pinion
Plunger sliding portion of magnetic switch
Reassembling Yoke Assembly
Before reassembly, make sure that no metallic parts
attach to the yoke assembly. Because of strong magnetic
force, hold the yoke assembly and insert it slowly into the
armature.
To r q u e
Torque for each part (See Torque Specifications in
this section)
Pinion Jump–out Dimension
Connect the “+” cable of battery to terminal S and the “–”
cable to terminal M. Turn the switch on, and measure
pinion travel dimension in thrust direction from the
jump–out position.
In measuring the dimension, pull the pinion out a little in
the arrow direction.
Dimension(L): 0.05 mm to 1.5 mm (0.002 in to
0.06 in)
065RS030

6D3–14STARTING AND CHARGING SYSTEM
If the measured value is out of standard, insert dust cover,
or disassemble and adjust.
065RW019
Characteristic Test
For easily confirming the characteristics, conduct the no
load test as follows:
Rating as short as 30 seconds requires rapid testing.
Fix the starter on the test bench, and wire as shown in
illustration. When the switch is closed, the current flows
and the starter runs under no load. At this time, measure
current, voltage and speed to check if they satisfy the
standard.
065RW020
Legend
(1) Volt Meter
(2) Tachometer
(3) Battery
(4) Ammeter
(5) Switch

6D3–15 STARTING AND CHARGING SYSTEM
Main Data and Specifications
General Specifications
ModelHITACHI GD002350
Rating
Voltage12 V
Output1.4 Kw
Time30 sec
Number of teeth of pinion 9
Rotating direction(as viewed from pinion)Clockwise
Weight(approx.)34 N
No load characteristics
Voltage /Current 11V/90A or less
Speed 2700rpm or more
Load characteristics
Voltage/current 8.4V/250A
Torque 7.3Nꞏm(64lbꞏin.) or more
Speed 1200rpm or more
Locking characteristics
Voltage/current 3V/750A or less
To r q u e19Nꞏm(14lbꞏin) or more

6D3–16STARTING AND CHARGING SYSTEM
Torque Specifications
Nꞏm (Kgꞏm/lb ft)
E06RW044

6D3–17 STARTING AND CHARGING SYSTEM
Nꞏm (Kgꞏm/lb ft)
150RW100

6D3–18STARTING AND CHARGING SYSTEM
Charging System
General Description
The IC integral regulator charging system and its main
components are connected as shown in the illustration.
The regulator is a solid state type and it is mounted along
with the brush holder assembly inside the generator
installed on the rear end cover.
The generator does not require particular maintenance
such as voltage adjustment.
The rectifier connected to the stator coil has eight diodes
to transform AC voltage into DC voltage.
This DC voltage is connected to the output terminal of
generator.
General On–Vehicle Inspection
The operating condition of charging system is indicated
by the charge warning lamp. The warning lamp comes on
when the starter switch is turned to “ON” position. The
charging system operates normally if the lamp goes off
when the engine starts.
If the warning lamp shows abnormality or if undercharged
or overcharged battery condition is suspected, perform
diagnosis by checking the charging system as follows:
1. Check visually the belt and wiring connector.
2. With the engine stopped, turn the stator switch to
“ON” position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal “L” on connector side.
If lamp comes on:
Repair or replace the generator.
F06RW009

6D3–19 STARTING AND CHARGING SYSTEM
Generator
Removal
1. Disconnect battery ground cable.
2. Move drive belt tensioner to loose side using wrench
then remove drive belt (1).
3. Disconnect the wire from terminal “B” and disconnect
the connector (4).
4. Remove generator fixing bolt (3).
5. Remove generator assembly (2).
060RW002
Inspection
1. Disconnect the wiring connector from generator.
2. With the engine stopped, turn starter switch to “ON”
and connect a voltmeter between connector terminal
L (2) and ground or between terminal IG (1) and
ground.
066RW001If voltage is not present, the line between battery and
connector is disconnected and so requires repair.
3. Reconnect the wiring connector to the generator, run
the engine at middle speed, and turn off all electrical
devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair or
replace the generator.
5. Connect an ammeter to output terminal of generator,
and measure output current under load by turning on
the other electrical devices (eg., head lights). At this
time, the voltage must not be less than 13V.
Installation
1. Install generator assembly to the position to be
installed.
2. Install generator assembly and tighten the fixing bolts
to the specified torque.
To r q u e :
M10 bolt: 41 Nꞏm (4.2 Kgꞏm/30 lb ft)
M8 bolt: 21 Nꞏm (2.1 Kgꞏm/15 lb ft)
3. Connect wiring harness connector and direct terminal
“B”.
4. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
5. Reconnect battery ground cable.