Opel Frontera

since 1992 of release

Repair and car operation



Fronter's Opel
+ Opel Frontera brand Cars
+ Current leaving and service
+ Engine
+ cooling and heating Systems
+ Power supply system and release
- Engine electric equipment
   + ignition System
   - Charge and start systems
      Storage battery
      Generator
      Starter
+ Coupling
+ Manual box of gear shifting
+ Driveshafts, main transfer
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Governing bodies and operation
+ electric equipment Schemes



Generator

GENERAL INFORMATION

Security measures at work with the generator

Before making any works on charging system, it is necessary to familiarize with the following security measures:
1. Never to disconnect the battery or a tension regulator when the engine and the generator work.
2. Never to close the excitement plug the generator or the cable fixed on it on weight.
3. Never to confuse wires of a regulator of tension.
4. Never to include a tension regulator if it is connected to weight (instant damage).
5. Never to remove the generator if the battery is not disconnected from a contour.
6. At installation of the battery to watch, that the minus plug was connected to weight.
7. Never to use the indicator of tension which is connected directly in a household network (110 or 220 In). To use only the indicator for 12 Century.
8. If the battery is charged in the established condition by the charger, both cables of the battery should be disconnected. The positive plug of the charger to connect to the positive plug of the battery, and the negative plug of the charger with the negative plug of the battery.
9. The wrong connection of wires leads to destruction of the rectifier and a tension regulator.

Check of the established generator


At normal movement the lamp of control of a charge should go out. Otherwise, malfunction consists in the generator or a tension regulator. First to check electric connections of the generator. To check, whether correctly will pull a driving belt. Further check can be carried out only on the removed generator, however it is possible to check all safety locks previously.

Service, check and generator repair


Remark: The generator and a regulator are not subject to settings and repair. It is possible to replace the idle generator on replaceable, having handed over the old generator upon purchase.

Service

Bearings of the generator have long-term greasing and do not demand regular maintenance. To keep outer side of the generator clean and not to allow hit on it of water or other dissolving means.

Check and repair


Brushes of the generator slide on smooth contact rings and consequently have very long service life. For check of brushes removal of the generator is not required. To do the following works:

Security measures at work with the charger


Work with the charger demands observance of the following security measures:
1. It is impossible to disconnect the storage battery or a tension regulator in operating time of the engine and respectively the generator.
2. Do not allow contact to mass of the plug of a winding of excitement of the generator or the cable attached to it.
3. At all do not interchange the position of a wire of a regulator of tension.
4. At all do not include a tension regulator if it is connected to weight it (will be immediately damaged).
5. At all do not remove the generator, without having disconnected previously the storage battery.
6. At installation of the storage battery watch that the negative plug incorporated to weight. Though plugs have different diameter, the mistake is possible.
7. At all do not apply the control lamp included directly in the main network (110 or 220 In). Apply only a control lamp tension of 12 Century.
8. At a charging of the storage battery without removal from the car both cables are necessary to disconnect it. The positive plug of the charger should incorporate to a positive pole of the battery, and negative with the negative.
9. The wrong connection of the charger conducts to damage of the rectifier and a tension regulator.
10. At replacement establish the generator of the corresponding current of return.

Generator check on the engine


At normal operation of the car the control lamp of the category of the storage battery should not burn. If the lamp burns, it indicates malfunction in the generator or a tension regulator.
At first it is necessary to check all accessions to the generator.
Check a tension of a maple belt. Other checks are carried out on the generator removed from the engine. It is recommended to lead them in a repair truck having special control equipment.

Removal and installation


For all executions disconnect a weight cable from the storage battery. Further depending on execution:

THE ENGINE OF 2.0 L TILL 1995. RELEASE


PERFORMANCE ORDER
1. Fastening of the generator is shown on иллюстр. Disconnect cables from a reverse side of the generator.
2. Remove a driving belt as it is described in the Head of System of cooling and heating for this engine. This execution has the device of adjustment of a tension of a belt.
3. Unscrew bolts of fastening of the generator from a tension level and from the bottom support (an arrow on an illustration).
At installation of the generator tighten fastening bolts by hand. Put on maple a belt and adjust its tension. After that tighten a bolt shown on иллюстр. also tighten bolts and nuts of the bottom fastening of the generator.
Attach cables from a reverse side of the generator. Attach a cable of weight of the storage battery.

THE ENGINE OF 2.0 L FROM THE MIDDLE OF 1995. RELEASE


Here it is necessary to carry out some preparatory work to reach the generator.

PERFORMANCE ORDER
1. Disconnect a weight cable from the storage battery.
2. Remove the details shown on иллюстр. It is a hose of absorption of air (1) between the case of a butterfly valve and the case of the air filter. Rasstykuyte shtekerny connection of a cable (2) from the sensor of temperature of soaked-up air and (3) measuring instruments of weight of soaked-up air.
3. Mark the direction of rotation of a belt with paint on outer side and turn a tension roller a cap key to the right so that it was possible to remove a belt.
4. Remove the generator according to иллюстр. For this purpose unscrew at first bolts of fastening (1) and (2), and then bolts (3) and (4). After that the bottom bolt of fastening of the generator is weakened. Reject the generator aside.
5. From a reverse side of the generator remove two cable supplies, completely take out the bottom bolt and take out the generator upward.

The generator in sequence is established, to return to removal. The bottom plug (plug 61) tighten the moment of 4 Nanometers, the top plug (plug 30) tighten the moment of 8 Nanometers. Watch that the cable correctly lay.
When fastening the generator maintain the next moments of an inhaling:

PERFORMANCE ORDER
1. Fastening bolts with (1) on (4) on иллюстр. tighten the moment of 18 Nanometers.
2. The bottom bolt of fastening is tightened by the moment of 35 Nanometers.
Put on maple a belt according to marking of the direction of rotation and pull a roller as it is described in appropriate section for the considered engine. In summary again establish the details shown on иллюстр.

THE DOHC ENGINE (VOLUME OF 2.2 L) FROM THE MIDDLE OF 1995. RELEASE


PERFORMANCE ORDER
1. As well as for the engine of 2.0 l it is necessary to carry out preliminary preparation to provide access to the generator. For this purpose disconnect shown on иллюстр. collars of fastening of hoses (1), (2), (3) and (7). Rasstykuyte shtekerny connections of a plait of cables (6) sensors of temperature of soaked-up air, a plait of cables of a measuring instrument of weight of air also remove a hose of soaked-up air (5) between the case of a butterfly valve and the case of the air filter.
2. Other details act in film similar to the engine of 2.0 l from the middle of 1995 of release, including generator fastening (see иллюстр.).
In the presence of the conditioner it is necessary to disconnect the pump of the hydraulic booster of a steering, having provided access to the bottom bolt of fastening of the generator. Hydraulic hoses of the pump are not disconnected. The pump put aside.

The generator according to the description for engines of 2.0 l from the middle of 1995 of release is established.

Adjustment of a tension of a maple belt


Adjustment of a tension of a maple belt of a drive of the generator is described in the Head of System of cooling and heating if it is a question of a maple belt with the tension device (the engine of 2.4 l to the middle of 1995 of release).

Repair of the generator of Bosch firm


Scheme of assembly of the Bosch generator

1-Coupling bolt
2-washer
3-remote ring
4-level of fastening of the bearing
5-ring
6-remote ring
7-bolt and spring washer
8-shponka
9-rotor
10-bearing
11-washer
12-a stator with diodes of rectifiers
13-stator
14-block of rectifiers
15-generator case
16-brushes
17-tension regulator
18-condenser of protection against hindrances

Dismantling

PERFORMANCE ORDER
1. According to иллюстр. the following works are performed:
2. Unscrew from a rotor shaft a nut and remove from a shaft a pulley and the fan with a remote washer. To hold a shaft from a provorachivaniye it is possible having thrown a pulley with an old belt and having clamped it in a vice. It is possible to insert also into a shaft opening a face key and to unscrew a nut a cap key, as is shown in иллюстр. To removal of a pulley it is applied two - or a trekhzakhvatny stripper.
3. Take out from a shaft a shponka.
4. Disconnect a tension regulator with a shchetkoderzhatel. Shchetkoderzhatel is from a reverse side and fastens two screws.
5. Mark the mutual provision of a cover from a drive and the case of the generator and turn out from the case coupling bolts (arrows on иллюстр.). Disconnect a back cover of the bearing from a forward cover. For this purpose it is possible to knock slightly with a plastic hammer on a cover.
6. Establish a cover from a drive and a rotor under a press and remove a rotor a trekhzakhvatny stripper, as is shown in иллюстр. At a vypressovka bolts of an external washer of fastening of the bearing break. It is necessary to watch that cams of a stripper were brought under a washer, and not just under a cover. If it is necessary to take out the bearing from a cover, unscrew bolts from the inside and выпрессуйте the bearing.
7. Remove the bearing from the opposite end of a rotor. If the stripper is for this purpose applied, bring its cams under an internal ring of the bearing.
8. Otpayayte from a stator the vypryamitelny block. For this wire between a stator and a tip of a soldering iron clamp tweezers for a heat-conducting path. Diodes should not overheat.
The Vypryamitelny block acts in film only in the presence of necessary experience and the tool.

Repair of brushes and shchetkoderzhatel

PERFORMANCE ORDER
1. Check quality of contact of brushes with contact rings. Check freedom of moving of brushes in directing shchetkoderzhatel. If necessary clear Tri liquid.
If the acting part of a brush is worn-out to 5 mm (иллюстр.), it is necessary to replace a brush, отпаяв it.

Rotor check


PERFORMANCE ORDER
1. If contact rings are greased, it is necessary to clear them a rag moistened in Tri liquid. At existence рисок polish them a skin.
For check of isolation of a winding of excitement of a rotor put one щуп an ohmmeter to the rotor core, and another щуп to a contact ring. The ohmmeter should show "infinity". Otherwise the rotor is subject to replacement (иллюстр.).
2. For check of a winding of excitement of a rotor on break put both tips of an ohmmeter to contact rings. The device should show 2.6 - 2.8 Ohm. If the ohmmeter shows "infinity", it indicates break in windings if shows "zero" on existence of short circuit (иллюстр.).

Stator check


PERFORMANCE ORDER
1. In the presence of short circuit in a stator winding owing to an overheat it is possible to establish it visually. Such stator is subject to replacement. Put one щуп an ohmmeter to a collector ring (1), another serially to each of three conclusions of a stator (2), (3), (4), (иллюстр.).
2. The device should show "infinity". For check of a winding of a stator on break serially connect stator conclusions among themselves. If the device does not give indications, it indicates break existence (иллюстр.). Resistance of windings should be equal 0.10 - 0.11 Ohm.

Check of the vypryamitelny block


Exact check of size of tension of the 45th transmission and value of a locking current of diodes demands existence of the special device and should be carried out in the conditions of repair trucks.

Assembly


PERFORMANCE ORDER
1. The scheme of assembly of the generator is shown on иллюстр. "Scheme of assembly of the Bosch generator". Napressuyte on a rotor shaft the bearing. The bearing in a cover from a drive fastens an external washer. After cover installation from a drive for the shaft end напрессовывается a remote ring (3). Before generator installation on the engine of the car it is necessary to check its work at the stand.

Replacement of brushes

PERFORMANCE ORDER
1a. As a result of long work of a brush wear out, reaching minimum admissible size. It is possible to replace brushes without performance of repair of the generator. However it is not recommended to carry out this work on Delco-Remy firm generators since it can cause certain difficulties. Here it is necessary to remove the generator and to hand over it in a repair truck.
On the Bosch firm generator this work can be executed after generator removal. However for this purpose it is necessary to have soldering experience. Unscrew from a reverse side of the generator two screws shown on иллюстр. shooters
1b. Cнимите the knot shown on иллюстр. It is knot of a shchetkoderzhatel and a tension regulator.
2. Measure length of an acting part of brushes. If the specified length less than 5 mm or comes nearer to this size, it is necessary to replace brushes. If length sufficient, check freedom of moving of brushes in directing shchetkoderzhatel. They should come back back under the influence of a tension of springs. If it does not occur, brushes also are replaced.
3. For replacement of its brush it is necessary отпаять. For this purpose take tweezers a brush rope (for a heat-conducting path) and отпаивают it.
Insert new brushes with springs in directing shchetkoderzhatel. Check, that brushes did not jam. In the presence of jamming smooth out the brush planes a small skin.
4. Solder a brush rope. Watch that solder did not leak along a rope since the rope thus becomes too rigid.
Wipe through openings in the generator a rag moistened in gasoline contact rings and insert into place shchetkoderzhatel. Watch that brushes rose on contact rings. Establish the generator on the engine.
Instruction: Carefully check, that brushes rose into place.