Opel Frontera UBS. Service manual — part 268
6D3–4
STARTING AND CHARGING SYSTEM
Diagnosis
Condition
Possible cause
Correction
Starter does not run
Charging failure
Repair charging system
Battery Failure
Replace Battery
Terminal connection failure
Repair or replace terminal connector
and/or wiring harness
Starter switch failure
Repair or replace starter switch
Starter failure
Repair or replace starter
6D3–5
STARTING AND CHARGING SYSTEM
Starter
Removal
1. Battery ground cable.
2. Remove exhaust front left pipe(1).
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3. Remove heat protector(3).
4. Disconnect starter wiring connector from terminals
“B” and “S”(4).
5. Remove starter assembly mounting bolts on inside
and outside(5).
6. 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/80 lb in)
4. Install heat protector(3).
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5. Install exhaust front left pipe and tighten bolts and
nuts to specified torque(2).
Stud Nuts
Torque: 67 N·m (6.8 Kg·m/49 lb ft)
Nuts
Torque: 43 N·m (4.4 Kg·m/32 lb ft)
150RW062
6. Reconnect the battery ground cable.
6D3–6
STARTING AND CHARGING SYSTEM
Disassembled View
065RW002
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).
065RW005
11. Raise a brush spring to detach brushes (4 pcs) from
the commutator face and pull off the brush holder(12)
and brush(11).
065RW006
12. Remove yoke assembly(14).
13. Remove armature(15).
14. Pull off the yoke assembly, then remove armature,
washer and center bracket.(A) (13).
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