Opel Frontera UE. Manual - part 1445

6D3–21

STARTING AND CHARGING SYSTEM (6VD1 3.2L)

Disassembly

1. Remove the through bolt.

Insert the tip of a pry bar into the gaps between the
front cover and the stator core.
Pry apart and separate the front cover, rotor, the rear
cover and stator.

NOTE: Take care not to scratch or otherwise damage the
stator coil with pry bar.

F06RT021

2. Clamp the rotor in a vise and then remove the nut and

pulley.

3. Remove the rotor assembly from front cover.

F06RT022

4. Remove screws with bearing retainer from front cover

and remove bearing.

F06RT023

5. Remove the mounting nuts holding the “B” terminal,

the diode, and the brush holder.

6. Separate the rear cover from the stator.

F06RT024

SECTION

6D3–22 STARTING AND CHARGING SYSTEM (6VD1 3.2L)

7. Remove bolts which secure stator terminal to rectifier

terminal, and remove stator.

066RS030

8. Remove Bolts which secure regulator, rectifier and

brush-holder, and separate these parts.

NOTE: Do not apply a shock or load to regulator, rectifier
and brush holder.

066RW025

Inspection and Repair

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

Rotor Assembly

1. Check the face of the slip rings for contamination and

roughness. If found to be scored, dress with a fine
sandpaper (#500 –600).  If found to be contaminated,
clean with a cloth saturated with alcohol.

2. Measure the outside diameter of the slip rings.

Standard: 27mm (1.06in)
Limit: 26mm (1.02in)

066RS032

3. Check resistance between slip rings, and replace if

there is no continuity.

Standard: 3.75

W

 or less

066RS033

SECTION

6D3–23

STARTING AND CHARGING SYSTEM (6VD1 3.2L)

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

In case of continuity, replace the rotor assembly.

066RS017

Stator Coil

1. Check for continuity across the stator coils.  If no

continuity exists, replace the coils.
Resistance value at 20

°

C.

Standard: Approx. 0.07

W

066RS034

2. Check for continuity across one of the stator coils and

stator core.  If a continuity exists, replace the coil.

Standard: More than 1M

W

066RS035

Brush

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

Standard: 18.0mm (0.709in)
Limit: 5.5mm (0.217in)

066RW024

Rectifier Assembly

1. Measure the resistance between each diode terminal

and aluminum diode fin in forward and reverse
directions with the connection of the tester leads
switched.  The diodes are normal if resistance is
nearly zero ohms in one direction and is infinitely high
in the other direction.

2. If a diode has no resistance or equal resistance in

both directions, it is defective and should be replaced
together with the holder.

SECTION

6D3–24 STARTING AND CHARGING SYSTEM (6VD1 3.2L)

066RS036

IC Regulator Assembly

Connect a variable resistor, two 12V batteries, a fixed
resistor, and a voltmeter to the IC regulator as shown in
illustration.

a. Measuring equipment specifications
1. Fixed resistor (R1) : 10 Ohms /3W
2. Variable resistor (Rv) : 0-300 Ohms/12W
3. Batteries (BAT1, BAT2) : 12V (2 Batteries)
4. DC voltmeter : 0-50V/0.5 steps (4 Check points)
b. Measuring procedure
1. Measure the voltage “V1” across the first battery

(BAT1). If the reading is between 10 and 13 volts,
the battery is normal.

2. Measure the voltage “V3” across both the batteries

(BAT1, BAT2). If the reading is between 20 and 26
bolts, the batteries are normal.

3. Gradually increase the resistance of the variable

resistor from zero.  Measure the voltage “V2” (the
voltage across the F and E terminals).

Check to see that the voltage across “V1” changes at
this time.  If there is no change, the voltage regulator
is faulty and must be replaced.

4. Measure the voltage at “V4” (the voltage across the

variable resistor center tap and terminal E with the
variable resistor resistance held constant).  The
measure voltage should be within the specified
(14.4

±

0.3 volts) limits.  If it is not, the regulator must

be replaced.

066RX003

Reassembly

To reassemble, follow the disassembly steps in the
reverse order, noting the following points:

NOTE:

D

Never make battery connections with polarities
reversed, or battery will be shorted via the diodes.
This will cause damage to the diodes.

D

Do not connect generator B terminal to ground; it is
connected directly to the battery.
This cable will burn if it is connected to ground.

D

Make sure to disconnect the positive (+) terminal of
the battery when quick-charging battery .
Diodes may be damaged due to abnormal pulse
voltage generated bye the quick charger.

D

When reassembling the front section to rear section,
insert a stiff wire into hole in the rear face of the rear
cover from the outboard side to support the brush in
raised position, then insert the front section to which
rotor is assembled.

D

Reassemble parts carefully to be sure they fit into
their original position, paying attention to the
insulated portions.

D

Wipe insulating tubes, washers and plates clean and
install them in position carefully to avoid getting oil or
grease on them.

SECTION