Opel Frontera UBS. Service manual — part 2241

6D3–21

STARTING AND CHARGING SYSTEM

Disassembly

1. Terminal insulator and nut(2).
2. Remove three nuts(1) on the rear cover and a nut on

terminal B and insulator, then remove the rear
cover(3).

060RW005

3. Remove two screws that fix the brush holder(5) and

rectifier, then remove the brush holder assembly(4).

060RW004

4. Remove three screws on the IC regulator, then the IC

regulator assembly(6).

060RW003

5. Remove four screws that fix rectifier(7) and stator

lead wires.

066RW004

6D3–22 STARTING AND CHARGING SYSTEM

6. Secure the pulley directly in the vise between two

copper plates, and remove the nut and pulley.

066RS010

7. Remove four nuts(8) that secure the front cover

assembly and rear end cover, and an insulator(9).

066RW005

8. Use the puller to remove the rear end cover.
9. Rotor assembly

066RS012

10. Pull the rotor assembly(10) off the front cover

assembly(12) using a bench press(11).

066RW006

6D3–23

STARTING AND CHARGING SYSTEM

Inspection and Repair

Repair or replace necessary parts if extreme wear or
damage is found during inspection.

Rotor Assembly

1. Check the rotor slip ring surfaces for contamination

and roughness. If rough, polish with #500—600
sandpaper.

066RS014

2. Measure the slip ring diameter, and replace if it

exceeds the limit.

066RS015

3. Check resistance between slip rings, and replace if

there is no continuity.

066RS016

4. Check for continuity between slip ring and rotor core.

In case of continuity, replace the rotor assembly.

066RS017

6D3–24 STARTING AND CHARGING SYSTEM

Stator Coil

1. Measure resistance between respective phases.
2. Measure insulation resistance between stator coil

and core with a mega–ohmmeter.
If less than standard, replace the coil.

066RS018

Brush

Measure the brush length.
If more than limit, replace the brush.

Standard: 10.mm (0.4134 in)

Limit: 8.4.mm (0.3307 in)

066RS019

Rectifier Assembly

Check for continuity across “P” and “E” in the

×

100W

range of multimeter.

066RW002

Change polarity, and make sure that there is continuity in
one direction, and not in the reverse direction. In case of
continuity in both directions, replace the rectifier
assembly.

IC Regulator Assembly

Check for continuity across “B” and “F” in the

×

100W

range of multimeter.

066RS021

Change polarity, and make sure that there is continuity in
one direction, and not in the reverse direction. In case of
continuity in both directions, replace the IC regulator
assembly.