Opel Frontera UBS. Manual - part 1304

STARTING SYSTEM 6D2 – 5

UNIT REPAIR

6D2 – 6 STARTING SYSTEM

DISASSEMBLY

1. Lead Wire Nut

•

Loosen the nut on terminal “M” of magnetic
switch and disconnect the connector cable.

2. Bolt (2 pcs)

3. Magnetic Switch Assembly

10. Motor Assembly

11. Brush Holder

•

Raise a brush spring to detach the negative side of
the brushes (2 pcs) from the commutator face and
remove the positive side of brushes (2pcs) from
the positive side of brushes (2pcs) from the brush
holder.

4. Torsion Spring

•

Remove torsion spring from magnetic switch
assembly.

5. Plunger

6. Shim

7. Magnetic Switch

8. Through Bolt

9. Rear Cover

•

Remove the through bolts, then remove the rear
cover.

12. Armature
13. Yoke Assembly
14. Bearing Retainer
15. Pinion Assembly
16. Bearing Holder
17. Bearing
18. Pinion Stopper Clip

•

Remove the stopper clip using a screw driver o
equivalent.

19. Pinion Stopper
20. Return Spring
21. Pinion Shaft
22. Clutch
23. Dust Cover
24. Shift Lever
25. Gear Case

STARTING SYSTEM 6D2 – 7

INSPECTION AND REPAIR

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

Armature

•

Measure the outer diameter of commutator, and
replace with a new one if it is out of the limit.

•

Check for continuity between commutator and
segments. Replace commutator if there is no
continuity (i.e., disconnected).

•

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).

•

Measure runout of armature core and commutator
with a dial gage.  Repair or replace, if it exceeds the
limit.

Name

Standard

Armature

0.05 (0.002) Max.

mm(in)

Conmutator

0.05 (0.002) Max.

0.1 (0.004)

0.1 (0.004)

Limit

Standard

Limit

38.0(1.50)

36.5(1.44)

mm (in)

6D2 – 8 STARTING SYSTEM

•

Polish the commutator surface with sand paper #500
to #600 if it is rough.

•

Measure the depth of insulator in commutator.  Re-
pair, if it is below the limit.

Brush

•

Measure the length of brush.
Replace with a new one, if it is below the limit.

Brush holder

•

Check for continuity between brush holder (+) and
base (-). Replace, if there is continuity (i.e., insulation
is broken).

•

Inspect the brush springs for wear, damage or other
abnormal conditions.

Standard

Limit

0.5 ~ 0.8 (0.02 ~ 0.03)

0.2 (0.008)

mm(in)

Standard

Limit

18.0 (0.71)

11.0 (0.43)

mm(in)

Standard

28-35 (2.9-3.6/6.4-7.9)

N (Kg/lb)