1998 OPEL FRONTERA battery

ENGINE ELECTRICAL 6D – 13
Pinion
1) Check by hand to see if the pinion rotates smoothly
in the dirve direction, or if it is locked when it is
rotated reversely.
If not, replace the pinion.
Yoke assembly
1) Check the magnet inside the yoke.
Replace the yoke assembly if it is broken.
REASSEMBLY
To install, follow the removal steps in the reverse order,
noting the following points:
Grease application places
1) Gears in reduction gear
2) Shift lever operating portion
3) Sliding potion of pinion
4) Plunger sliding portion of magnetic switch
Pinion jump-out dimension
1) Connect the (+) cable of battery to terminal S and
the (–) cable to terminal M. Turn the switch on, and
measure pinion travel dimension “L” in thrust
direction from the jump-out position.
In measuring the dimension, pull the pinion out a little in
the arrow direction.
Dimension L: 0.3 – 1.5 mm (0.01 – 0.06 in)If the measured value is out of standard, adjust the of
shims.
Legend
(1) Shim
065RW048
S
+
L M
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1
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6D – 14 ENGINE ELECTRICAL
MAGNETIC SWITCH
Pull-out test
Connect the magnetic switch to the battery as shown.
The negative side to the “M” terminal and the magnetic
switch body (housing); the positive side to the “S”
terminal. If the pinion has been ejected, the pull-in coil
is satisfactory.
Legend
(1) Terminal “S”
(2) Terminal “M”
(3) Starter
(4) For Return Test
(5) For Hold-In Test
Hold-in test
1. Next disconnect the “M” terminal.
2. The pinion should remain in the ejected position.
Return test
When the switch body is disconnected, the pinion
should return quickly.
2 1
5
3
4
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ENGINE ELECTRICAL 6D – 15
CHARGING SYSTEM
GENERAL DESCRIPTION
GENERATOR
CHARGING CIRCUIT
The charging system is the IC integral regulator
charging system and its main components are
connected as shown in Figure.
The regulator is a solid state type and it is mounted
along with the brush holder assembly inside the
generator installed on the rear end cover.The generator does not require particular maintenance
such as voltage adjustment. The rectifier connected to
the stator coil has nine diodes to transform A.C. voltage
into D.C. voltage. This D.C. voltage is connected to the
output terminal of generator.
A06RW001
Condenser
GeneratorStator Coil
IC RegulatorStarter
SW
Rotor Coil
Battery
P F
EBS LRelay B
S
L
QOS
C/U
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6D – 16 ENGINE ELECTRICAL
DIAGNOSIS
GENERAL ON-VEHICLE INSPECTION
The operating condition of the charging system is
indicated by the charge warning lamp. The warning
lamp comes on when the starter swtich is turned to
“ON” position. The charging system operates normallyif the lamp goes off when the engine starts. If the
warning lamp shows abnormality or if undercharged or
overcharged battery condition is suspected, perform
diagnosis by checking the charging system as follows:
Condenser
GeneratorStator Coil
IC RegulatorStarter
SW
Rotor Coil
Battery
P F
EBS LRelay B
S
L
QOS
C/U
065RW00001
1. Check visually the belt and wiring connector.
2. With the engine in stop status, turn the starter
switch to “ON” position and observe the warning
lamp.
1) If lamp does not come on:
Disconnect wiring connector from generator,
and ground terminal “L” on connector side.
2) If lamp comes on:
Repair or replace the generator.

ENGINE ELECTRICAL 6D – 21
Rectifier Assembly
1. Measure the resistance between each diode
terminal and aluminum diode fin in forward and
reverse directions with the connection of the tester
leads switched. The diodes are normal if resistance
is nearly zero ohms in one direction and is infinitely
high in the other direction.
2. If a diode has no resistance or equal resistance in
both directions, it is defective and should be
replaced together with the holder.
IC Regulator Assembly
Connect a variable resistor, two 12V batteries, a fixed
resistor, and a voltmeter to the IC regulator as shown in
illustration.
a. Measuring equipment specifications
1. Fixed resistor (R1) : 10 Ohms / 3W
2. Variable resistor (Rv) : 0 – 300 Ohms / 12W
3. Batteries (BAT1, BAT2) : 12V (2 Batteries)
4. DC voltmeter : 0 – 50V / 0.5 steps (4 Check points)
b. Measuring procedure
1. Measure the voltage “V1” across the first battery
(BAT1). If the reading is between 10 and 13 volts,
the battery is normal.
2. Measure the voltage “V3” across both the batteries
(BAT1, BAT2). If the reading is between 20 and 26
bolts, the batteries are normal.
3. Gradually increase the resistance of the variable
resistor from zero. Measure the voltage “V2” (the
voltage across the F and E terminals).
Check to see that the voltage across “V1” changes
at this time. If there is no change, the voltage
regulator is faulty and must be replaced.
4. Measure the voltage at “V4” (the voltage across the
variable resistor center tap and terminal E with the
variable resistor resistance held constant). The
measure voltage should be within the specified
(14.4 ± 0.3 volts) limits. If it is not, the regulator
must be replaced.
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
NOTE:
1) Never make battery connections with polarities
reversed, or battery will be shorted via the diodes.
This will cause damage to the diodes.
2) Do not connect generator B terminal to ground; it is
connected directly to the battery.
This cable will burn if it is connected to ground.
3) Make sure to disconnect the positive (+) terminal of
the battery when quick-charging battery.
Diodes may be damaged due to abnormal pulse
voltage generated by the quick charger.
4) When reassembling the front section to rear
section, insert a stiff wire into hole in the rear face
of the rear cover from the outboard side to support
the brush in raised position, then insert the front
section to which rotor is assembled.
5) Reassemble parts carefully to be sure they fit into
their original position, paying attention to the
insulated portions.
6) Wipe insulating tubes, washers and plates clean
and install them in position carefully to avoid getting
oil or grease on them.
066RS036
R
EBS
R1RV
BAT2 BAT1
V2V3
V4V1＋
−
＋
−
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6D – 22 ENGINE ELECTRICAL
1. Using a press with a socket wrench attached,
reassemble rotor and rear end cover assembly in
the front cover.2. Install pulley on the rotor.
Secure the pulley directly in the vise between two
copper plates, and tighten nut to the specified
torque.
Torque: 111 Nꞏm (82 lb ft)
066RS022
066RS010
MAIN DATA AND SPECIFICATIONS
General Specifications
Model LR160-734B LR-170-760
Battery voltage V 12
Rated output A 60 70
Direction of rotation Clockwise
(as viewed from pulley side)
Rated rotation speed rpm 5,000
Maximum speed rpm 18,000

6D – 24 ENGINE ELECTRICAL
1 Inspection on Quick Heating Operation
1. Disconnect ECT-sensor connection on the
thermostat housing
Legend
(1) ECT Sensor
(2) EVRV
2. Connect the circuit tester between glow plug and
engine earth.
3. Inspect the following items with starter switch set to
ON position (but do not start the engine).
1) The glow indicator shall light for about 5 sec.
2) The circuit tester shall indicate power supply
voltage for 9 – 13 sec.
If above specifications are not satisfied, inspect
wire harness, glow relay and ECT-sensor. If
satisfied, inspect glow plug.2 Inspection on Afterglow Operation
1. Disconnect ECT-sensor connection on the
thermostat housing
Legend
(1) ECT Sensor
(2) EVRV
2. Connect the circuit tester between glow plug and
engine earth.
3. Inspect the following item with the engine started.
1) The circuit tester shall indicate about 7 volts
after 360 seconds of engine start.
If above specifications are not satisfied, inspect
battery voltage, engine earth, wiring harness,
glow plug, and ECM.
12
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12
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INSPECTION ON QOS4 SYSTEM OPERATION

ENGINE ELECTRICAL 6D – 25
ECT SENSOR
Measure the resistance depending on the water
temperature.
Temperature (°C) Current (mA) Resistance (k
)
20 ± 1 1.0 2.0 – 3.0
50 ± 1 1.0 0.6 – 1.0
When installing the ECT sensor, apply sealant (Loctite
#262 or equivalent) to prevent water leakage.
Torque: 8 Nꞏm (0.8 kgꞏm/69 lb in)
Legend
(1) Sealing Material
GLOW PLUG
Inspect the resistance
Resistance at normal temperature: 0.8 – 1.0
Torque: 23 Nꞏm (2.3 kgꞏm/17 lbꞏft)
GLOW PLUG RELAY
Inspect the continuity
(2) – (4) No Continuity
(1) – (3) Continuity
If battery voltage is applied to the terminal between (1)
– (3)
(2) – (4) Continuity065RW058
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1
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2 42
311
34
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