1998 OPEL FRONTERA charging

ENGINE ELECTRICAL6D1–3
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE – The battery is
good and should be returned to service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED –
Replace battery.
ESTIMATED TEMPERATURE
MINIMUM
VOLTAGE
FCV
70219.6
60169.5
50109.4
4049.3
30–19.1
20–78.9
10–128.7
0–188.5
The battery temperature must be estimated by feel
and by the temperature the battery has been
exposed to for the preceding few hours.
Battery Charging
Observe the following safety precautions when charging
the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate of
charge reduced if the battery feels hot to the touch.
Battery charging should be discontinued or the rate of
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot
or ring, it may be necessary to jiggle or tilt the battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be either
quick charged or slow charged in the same manner as
other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW THE
JUMP STARTING PROCEDURE COULD RESULT IN
THE FOLLOWING:
1. Serious personal injury, particularly to your eyes.
2. Property damage from a battery explosion, battery
acid, or an electrical fire.
3. Damage to the electronic components of one or both
vehicles particularly.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect your eyes by wearing
an approved set of goggles.
Never allow battery fluid to come in contact with your eyes
or skin.
Never allow battery fluid to come in contact with fabrics or
painted surfaces.
Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly
rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector level in the “PARK”
position.
If the vehicle is equipped with a manual transmission,
place the shift lever in the “NEUTRAL” position.
Turn “OFF” the ignition.
Turn “OFF” all lights and any other accessory
requiring electrical power.
2. Look at the built–in hydrometer.
If the indication area of the built–in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will
cause a ground connection, effectively neutralizing
the charging procedure.
Be sure that the booster battery has a 12 volt rating.

6D3–1 STARTING AND CHARGING SYSTEM
ENGINE
STARTING AND CHARGING SYSTEM
CONTENTS
Service Precaution 6D3–1. . . . . . . . . . . . . . . . . . . . . .
Starting System 6D3–2. . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6D3–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6D3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 6D3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3–6. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3–7. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3–9. . . . . . . . . . . . . . . . . .
Reassembly 6D3–13. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3–15. . . . . . . . . . .
Charging System 6D3–18. . . . . . . . . . . . . . . . . . . . . . . . General Description 6D3–18. . . . . . . . . . . . . . . . . . . . .
General On–Vehicle Inspection 6D3–18. . . . . . . . . . .
Generator 6D3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6D3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3–20. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3–23. . . . . . . . . . . . . . . . . .
Reassembly 6D3–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Bench Test 6D3–25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3–26. . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

6D3–2STARTING AND CHARGING SYSTEM
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.
Starter
The cranking system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion
shaft. When the starter switch is turned on, the contacts of
magnetic switch are closed, and the armature rotates. At
the same time, the plunger is attracted, and the pinion is
pushed forward by the shift lever to mesh with the ring
gear.
Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from the ring
gear, and the armature stops rotation. When the engine
speed is higher than the pinion, the pinion idles, so that
the armature is not driven.

6D3–3 STARTING AND CHARGING SYSTEM
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6D3–4STARTING AND CHARGING SYSTEM
Diagnosis
ConditionPossible causeCorrection
Starter does not runCharging failureRepair charging system
Battery FailureReplace Battery
Terminal connection failureRepair or replace terminal connector
and/or wiring harness
Starter switch failureRepair or replace starter switch
Starter failureRepair 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 Nꞏm (4.1 Kgꞏm/30 lb ft)
3. Reconnect the connectors to terminals “B” and “S”
and tighten Terminals “B” to specified torque.
Torque: 9 Nꞏm (0.9 Kgꞏm/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 Nꞏm (6.8 Kgꞏm/49 lb ft)
Nuts
Torque: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
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6. Reconnect the battery ground cable.

6D3–6STARTING 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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12. Remove yoke assembly(14).
13. Remove armature(15).
14. Pull off the yoke assembly, then remove armature,
washer and center bracket.(A) (13).