Opel Frontera UBS. Manual - part 2237

6D3–5

STARTING AND CHARGING SYSTEM

Starter

Removal

1. Battery ground cable.
2. Disconnect Heated O

2

 Sensor connector (1).

3. Remove exhaust front left pipe(2).

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4. Remove heat protector(3).
5. Disconnect starter wiring connector from terminals

“B” and “S”(4).

6. Remove starter assembly mounting bolts on inside

and outside(5).

7. Remove starter assembly toward the bottom of

engine(6).

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Installation

1. Install starter assembly(6).
2. Install mounting bolts and tighten bolts to specified

torque(5).

Torque: 40 N·m (4.1 kg·m/30 lb ft)

3. Reconnect the connectors to terminals “B” and “S”

and tighten Terminals “B” to specified torque.

Torque: 9 N·m (0.9 kg·m/78 lb in)

4. Install heat protector(3).

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5. Install exhaust front left pipe (2) and tighten bolts and

nuts to specified torque.

Stud Nuts
Torque: 67 N·m (6.8 kg·m/49 lb ft)
Nuts (Exhaust front left pipe–Right pipe)
Torque: 57 N·m (5.8 kg·m/42 lb ft)
Nuts (Exhaust front left pipe–Silencer)
Torque: 43 N·m (4.4 kg·m/32 lb ft)

6. Connect Heated O

2

 Sensor connector (1).

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7. Reconnect the battery ground cable.

6D3–6

STARTING AND CHARGING SYSTEM

Disassembled View

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Legend

(1) Bolt (2 pcs)
(2) Ball Bearing
(3) Pinion
(4) Shift Lever
(5) Dust Cover
(6) Torsion Spring
(7) Dust Cover
(8) Magnetic Switch
(9) Nut

(10) Gear Case

(11) Bearing Cover

(12) E–Ring
(13) Thrust Washer (2)

(14) Center Bracket
(15) Pinion Shaft
(16) Planet Gear (3)
(17) Internal Gear
(18) Center Bracket (A)
(19) Yoke Assembly
(20) Armature
(21) Brush
(22) Brush Holder
(23) Thrust Washer
(24) Rear Cover
(25) Screw (2 pcs)
(26) Through Bolt (2 pcs)

6D3–7

STARTING AND CHARGING SYSTEM

Disassembly

1. Loosen the nut(1) on terminal “M” of magnetic switch

and disconnect the connector cable.

2. Remove bolt (2 pcs) (2).

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3. Remove magnetic switch(5).
4. Remove dust cover(4).
5. Remove torsion spring bolts, then the magnetic

switch assembly.

6. Remove torsion spring(3) from magnetic switch

assembly(5).

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7. Remove screw (2 pcs) (8).
8. Remove through bolt (2 pcs) (7).
9. Remove screws and through bolts, then the rear

cover(9) then remove thrust washer(10).

10. Remove brush holder(6).

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11. Raise a brush spring to detach brushes (4 pcs) from

the commutator face and pull off the brush holder(12)
and brush(11).

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6D3–8

STARTING AND CHARGING SYSTEM

12. Remove yoke assembly(14).
13. Remove armature(15).
14. Pull off the yoke assembly, then remove armature,

washer and center bracket.(A) (13).

NOTE: In disassembling the yoke assembly, hold the
armature and pull off slowly the yoke assembly. Because
of strong magnetic force, avoid placing a metallic part
near armature.

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15. Remove dust cover(17).
16. Remove a dust cover and shift lever(16) from the gear

case.

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17. Remove ball bearing(19).
18. Remove bearing cover(20).
19. Remove a ball bearing and bearing cover from the

gear case(18).

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20. Internal gear(21).
21. Remove internal gear and planet gear(3) (22).

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