Opel Frontera UBS. Manual - part 2238

6D3–9

STARTING AND CHARGING SYSTEM

22. Remove an E–ring(23) from the pinion shaft using a

flat blade screwdriver.

065RW010

23. Holding the pinion shaft, push pinion toward the

center bracket. and turn the pinion clockwise or
counterclockwise by one tooth of spline, then pull off
the pinion.

24. Remove thrust washer(24).
25. Remove center bracket
26. Remove pinion shaft.

065RW011

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.

Standard: 33.0 mm (1.30 in)
Limit: 32.0 mm (1.26 in)

065RS014

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

065RS015

6D3–10 STARTING 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).

065RS016

Measure 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.

065RW012

Measure the depth of insulator in commutator.  Repair, if it
is below the limit.

Standard: 0.5 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

6D3–12 STARTING 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