Chapter 5 Part A: Starting and charging systems Contents A1temator - removal and refitting . .................. . ... .. .. 6 A1temator brushes and regulator - inspection and renewal ... . . .. 7 Auxiliary drivebelt - check and renewal . .. . . . . ...... See Chapter 1 Battery - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 Battery - testing and charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 Battery check .. . .. . .......... . . . . . . .. . . ... . See Weekly checks Charging system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5 Bectrical fault finding - general information ... . . . .. . . . . .... ... 2
Degrees of difficulty
Electrical system check ... ... ... . See Weekly checks and Chapter 1 General information and precautions . .. . . . . ...... .. ......... 1 Ignition switch - removal and refitting ........ . .. .... .. . ...... 11 Oil pressure waming light switch - removal and refitting ... ... ... 12 Starter motor - brush renewal .. .. ......... . ... ... . .. .. . . . . . 1 0 Starter motor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 9 Starting system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Easy, suitable for novice with little experience
~ Fair1y easy, suitable ~ ~ for beginner with ~ ~ some experience ~
Fair1y difficult, ~
suitable for competent ~ DIY mechanic ~
Difficult, suitable for ~ experienced DIY ~
mechanic ~
Very difficult, ~ suitable for expert DIY ~ or professional ~
Specifications General Bectrical system type . .. . .. . ...... ... ..... .. . . .... . . ... .... .
Battery Type . . ... . ...... • .. . . . . .. . . . . ... . ... ... .. . ... .. ... . . . Battery capacity ... .. .. ... . • . .. .... . . .. .. .. .. .... .. .. ... ...
Alternator Type . .. . ... ... .. •.... ... .. . ... .. ...... . .... . . . .... . .. Maximum output:
Bosch ............ . .... . ... . . , . . ... . ..... . ... . ... .. ... . Delco-Remy .. ... . . . . .. ... .. .. . .... .• .. . . . .. .. •. . ..•. .. .
Regulated voltage . ..... . ... .. ... . . .. . . . .. . .. ....... .... . . . . Brush minimum length:
Bosch .. ... .... . . . ..... .. . ..... ... ... .... . . . . . .. . . .... . Delco-Remy:
67 amp .. . .... .. . .. .. . . .. . .. ... . . . . ... . . . . .. . . . . . . .. . 100 amp .. ...... . .. . . . .... . . .. . . .... ... ...... .... ... .
Starter motor Type .. . .. .. .... . . ... . . ... .. .... . .. .. .. . .. . . ... .. . ... . Brush minimum length:
Delco-Remy: Except code number 09 000 756 ... . .... ... .... . .... ... .. . Code number 09 000 756 . . .. ... . .... .. ... . .... . .. . . . . .. .
Val eo
12 volt negative earth
Lead-acid, 'maintenance-free' (sealed for life) 36, 44, 55 or 60 Ah (depending on model)
Bosch or Delco-Remy
55 or 70 amps (depending on model) 67 or 100 amps (depending on model) 13.7 to 14.7 volts (approximately)
5.0mm
12.0 mm 20.0 mm
Pre-engaged, Delco-Remy or Valeo
4.0mm 8.5mm 13.0 mm
5A-2 Starting and charging systems
Torque wrench settings Nm Alternator adjuster strut-to-inlet manifold bolts:
Models with V-belt ........ ... .. ... .... . . ......... . . .. . .. . 20 Alternator (auxiliary) drivebelt tensioner lower mounting bolt:
Models with ribbed belt ..... . . . ....... .. ... . .. .... . .•. . .. . 20 Alternator (auxiliary) drivebelt tensioner roller-to-engine bolt:
Models with ribbed belt ............ .. . . .... ... . .......... . 20 Alternator mounting bracket-to-engine bolts (M1 0) ... . .. . . . . . . ... . 40 Alternator-to-adjuster strut bolts:
Models with V-belt ... . .... . ... . .. . . . ... . . . .. . ... . . . .... . . 20 Alternator-to-mounting bracket bolts:
M8 . ... ...... . . .. .... .... .. . .. ..... . .. . . .... .. ... .. . 30 M10 .. . .... .. . . .. .. ...... .. ... .. . ....... ... . .• .... ... 40
Alternator upper support bracket to alternator: Models with V-belt . . .. . ...... . .. . . ....... ... ....... .... . . 20
Alternator upper support bracket to inlet manifold: Models with V-belt .. . ................... . ...... . . ...... . . 20
Inlet manifold support bracket to cylinder block ...• . ... ... .. . . . . . Inlet manifold support bracket to inlet manifold:
20
1.0 litre DOHC engines . . .... ...... . . .......•....•. . . . . . ... 1 .2 litre DOHC engines ...... . .. . .........•. . .. ...... . . ... .
10 6
Starter motor bolts ......... . •.... .. . .... .. .. ... .... . .. .. . .. 25
1 General information and precautions
General information The engine electrical system consists
mainly of the charging and starting systems (covered in this Part of Chapter 5) and the ignition system (covered in Part B of this Chapter). Because of their engine-related functions , these components are covered separately from the body electrical devices such as the lights, instruments, etc (which are covered in Chapter 12).
The electrical system is of the 12 volt negative earth type.
The battery is of the 'maintenance-free' (sealed for life) type, and is charged by the alternator, which is belt-driven from a crankshaft-mounted pulley.
The starter motor is of the pre-engaged type, incorporating an integral solenoid . On starting , the solenoid moves the drive pinion into engagement with the flywheel ring gear before the starter motor is energised. Once the engine has started, a one-way clutch prevents the motor armature being driven by the engine while the pinion disengages from the flywheel.
Further details of the various systems are given in the relevant Sections of this Chapter. While some repair procedures are given, the usual course of action is to renew the component concerned . The owner whose interest extends beyond mere component renewal should obtain a copy of the Automobile Electrical & Electronic Systems Manual, available from the publishers of this manual.
Precautions It is necessary to take extra care when
working on the electrical system , to avoid damage to semi-conductor devices (diodes and transistors) , and to avoid the risk of personal injury. In addition to the precautions given in Safety first! at the beginning of this manual, observe the following when working on the system:
Always remove rings, watches, etc, before working on the electrical system. Even with the battery disconnected, capacitive discharge could occur if a component's live terminal is earthed through a metal object. This could cause a shock or nasty burn.
Do not reverse the battery connections. Components such as the alternator, ignition system components, or any other components having semiconductor circuitry, could be irreparably damaged.
If the engine is being started using jump leads and a slave battery, connect the batteries as shown in the preliminary section of this manual (see 'Jump starting? This also applies when connecting a battery charger.
Never disconnect the battery terminals, the alternator, any electrical wiring, or any test instruments, when the engine is running.
Do not allow the engine to turn the alternator when the alternator is not connected.
Never 'test' for alternator output by 'flashing' the output lead to earth.
Never use an ohmmeter of the type incorporating a hand-cranked generator for circuit or continuity testing.
Always ensure that the battery negative
Ibfft
15
15
15 30
15
22 30
15
15 13
7 4 18
lead is disconnected when working on the electrical system.
Before using electric-arc welding equipment on the car, disconnect the battery, alternator and components such as the engine management and the ABS electronic control units to protect them from the risk of damage.
Several systems fitted to the vehicle require battery power to be available at all times, either to ensure their continued operation (such as the clock) or to maintain control unit memories or security codes which would be wiped if the battery were to be disconnected. To ensure that there are no unforeseen consequences of this action, Refer to 'Disconnecting the battery' in the Reference Chapter for further information.
2 Electrical fault finding -general information
Refer to Chapter 12.
3 Battery-testing and charging
Note: The following information refers only to the maintenance-free type battery fitted as original equipment. 1 Topping-up and testing of the electrolyte in each battery cell is not possible. The condition of the battery can therefore only be tested by observing the battery condit ion indicator.
2 The battery condition indicator is located in the top of the battery casing, and indicates the condition of the battery by its colour (see illustration). If the indicator shows green,
en the battery is in a good state of charge. If the indicator turns darker, eventually to black, then the battery requires charging, as described later in this Section. If the indicator shows clear/yellow, then the electrolyte level in the battery is too low to allow further use, and the battery should be renewed. Do' not attempt to charge, load or jump start a battery when the indicator shows clear/yellow. 3 If the battery is to be charged , remove it from the vehicle, as described in Section 4, and charge it as follows. 4 The maintenance-free type battery takes considerably longer to fully recharge than the s andard type, the time taken being dependent on the extent of discharge. 5 A constant-voltage type charger is required; connect it up and set it to 13.9 to 14.9 volts, with a charge current below 25 amps. 6 If the battery is to be charged from a fullydischarged state (less than 12.2 volts output), have it recharged by a Vauxhall/Opel dealer or a competent automotive electrician, as the charge rate is high, and constant supervision during charging is necessary.
4 Battery-removal and refitting
ote: Refer to 'Disconnecting the battery' in e Reference Section of this manual before
proceeding.
Removal 1 On right-hand drive models, the battery is located on the left-hand side of the engine compartment , towards the rear. On left-hand
. e models the battery is located under the - screen cowl panel on the right-hand side. o remove the cowl panel, undo the five
screws, lift the panel up in the centre and remove the right-hand half forwards from the plenum chamber. 2 Disconnect the lead(s) at the negative (earth) terminal by unscrewing the retaining nut and removing the terminal clamp. 3 Disconnect the positive terminal lead(s) in the same way.
3.2 Battery condition indicator (arrowed)
Starting and charging systems 5A-3
4 Unscrew the clamp bolt sufficiently to enable the battery to be lifted from its location (see iliustration). Keep the battery upright. S If necessary the battery tray can be removed after undoing the four retaining bolts. Release any wiring or hose clips from the tray and lift the tray from the engine compartment.
Refitting 6 Refitting is a reversal of removal, but smear petroleum jelly on the terminals when reconnecting the leads, and always reconnect the positive lead first, and the negative lead last.
5 Charging system - testing ~
~ ~
Note: Refer to the precautions given in 'Safety first!' and in Section 1 of this Chapter before starting work. 1 If the ignition/no-charge warning light fails to illuminate when the ignition is switched on, first check the alternator wiring connections for security_ If satisfactory, check that the warning light bulb has not blown, and that the bulbholder is secure in its location in the instrument panel. If the light still fails to illuminate, check the continuity of the warning light feed wire from the alternator to the bulbholder. If all is satisfactory, the alternator is at fault, and should be renewed, or taken to an auto-electrician for testing and repair. 2 If the ignition warning light illuminates when the engine is running, stop the engine and check that the drivebelt is correctly tensioned (see Chapter 1) and that the alternator connections are secure. If all is so far satisfactory, check the alternator brushes and slip rings (see Section 7). If the fault persists, the alternator should be renewed, or taken to an auto-electrician for testing and repair . 3 If the alternator output is suspect even though the warning light functions correctly, the regulated voltage may be checked as follows. 4 Connect a voltmeter across the battery terminals, and start the engine. 5 Increase the engine speed until the voltmeter reading remains steady; the reading should be approximately 12 to 13 volts, and no more than 14 volts.
4.4 Unscrewing the battery clamp bolt
6 Switch on as many electrical accessories (eg , the headlights, heated rear window and heater blower) as possible, and check that the alternator maintains the regulated voltage at around 13.5 to 14.5 volts. 7 If the regulated voltage is not as stated, the fault may be due to worn brushes, weak brush springs, a faulty voltage regulator, a faulty diode, a severed phase winding , or worn or damaged slip rings. The brushes and slip rings may be checked (see Section 7), but if the fault persists, the alternator should be renewed , or taken to an auto-electrician for testing and repair.
6 Alternator -removal and refitting
SOHC engines with V-belt Removal 1 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Chapter). 2 Remove the auxiliary drivebelt as described in Chapter 1. 3 Disconnect the wires from their terminals on the rear of the alternator, noting their locations, or disconnect the wiring plug, as applicable. Note that on certain models, access to the alternator wiring may be easier from underneath the vehicle. 4 On models with multi-point fuel injection , remove the throttle body as described in Chapter 48, Section 13. 5 Unscrew the bolt securing the top of the alternator to the adjuster strut, and recover any washers and insulating bushes, noting their locations. Note the earth strap attached to the bolt. 6 Loosen the bolt securing the adjuster strut to the inlet manifold, and pivot the strut upwards to leave sufficient space to remove the alternator. 7 Undo the bolts securing the alternator upper support bracket to the alternator and inlet manifold and remove the bracket. 8 Support the alternator, then remove the nut and through-bolt securing the alternator to the engine bracket. Again , recover any washers and insulating bushes, noting their locations. 9 Withdraw the alternator from the engine.
Refitting
10 Refitting is a reversal of removal, bearing in mind the following points: a) Ensure that all washers and insulating
bushes are refitted in their correct locations, as noted before removal.
b) Ensure that the earth lead is refitted to the top alternator securing bolt.
c) Where applicable, refit the throttle body as described in Chapter 48.
d) Refit and tension the auxiliary drivebelt as described in Chapter 1.
5A-4 Starting and charging systems
6.13 Unbolt the two upper alternator mounting brackets (arrowed) - SOHC
engines with ribbed belt alternator drive
SOHC engines with ribbed belt
Removal 11 Proceed as described in paragraphs 1 to 3 inclusive, but note that it is only necessary to release the auxiliary drivebelt from the alternator pulley, it does not have to be removed completely. 12 Remove the nut and through-bolt securing the alternator to the lower bracket. Recover any washers and insulating bushes, noting their locations. 13 Support the alternator, then unbolt the two upper mounting brackets from the alternator, cylinder head and inlet manifold , and withdraw the brackets (see illustration). Again , recover any washers and insulating bushes, noting their locations. Note the earth strap attached to the front mounting bracket bolts. 14 Withdraw the alternator from the engine.
Refitting 15 Refitting is a reversal of removal , bearing in mind the following points: a) Ensure that any washers and insulating
bushes are refitted in their correct locations, as noted before removal.
b) Ensure that the earth lead is refitted to the front mounting bracket.
6.27 Unbolt the crankshaft speed/position sensor bracket from the oil pump.
Securing bolt arrowed - 1.4 and 1.6 litre DOHC engines
6.18 Auxiliary drive belt automatic tensioner lower mounting bolt (arrowed) -
1.0 and 1.2 litre DOHC engines
c) Do not fully tighten any of the mounting bolts until the alternator and all mounting brackets are in position.
d) Refit the auxiliary drivebelt as described in Chapter 1.
1.0 and 1.2 litre DOHC engines 16 Proceed as described in paragraphs and 2 , but note that it is only necessary to release the auxiliary drivebelt from the alternator pulley, it does not have to be removed completely. 17 If not already done, apply the hand brake, then jack up the front of the vehicle and support securely on axle stands (see Jacking and vehicle support) . 18 Undo the auxiliary drivebelt automatic tensioner lower mounting bolt, and swing the tensioner upwards to provide access to the lower alternator mounting bolt (see illustration). 19 Disconnect the wires from their terminals on the rear of the alternator, noting their locations. 20 Remove the nut and through-bolt securing the alternator to the lower mounting bracket. Recover any washers and insulating bushes, noting their locations (see illustration). 21 Support the alternator, then remove the nut and through-bolt securing the alternator to the upper mounting bracket. Again , recover
6.29 Alternator wiring securing nuts (arrowed) - 1.4 and 1.6 litre DOHC engines
(viewed from underneath vehicle)
6.20 Alternator upper and lower mounting through-bolt nuts - 1.0 and 1.2 litre DOHC
engines
any washers and insulating bushes, noting their locations. 22 Slide the alternator off the mounting brackets and remove it from under the car.
Refitting 23 Refitting is a reversal of removal , bearing in mind the following points: a) Ensure that any washers and insulating
bushes are refitted in their correct locations, as noted during removal.
b) Refit the auxiliary drivebelt as described in Chapter 1.
1.4 and 1.6 litre DOHC engines
Removal 24 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Chapter). 25 Remove the auxiliary drive belt as described in Chapter 1. 26 Apply the handbrake, then jack up the front of the vehicle and support securely on axle stands (see Jacking and vehicle support) . Remove the right-hand front roadwheel. 27 Unbolt the crankshaft speed/position sensor bracket from the oil pump, and move the bracket/sensor assembly to one side (take care not to damage the sensor or the wiring) (see illustration). 28 Disconnect the wiring from the oil pressure switch, located in the end of the oil pump. 29 Disconnect the wires from their terminals on the rear of the alternator, noting their locations, or disconnect the wiring plug, as applicable (see illustration). 30 Disconnect the outer end of the driveshaft from the front swivel hub assembly, as described in Chapter 8. There is no need to withdraw the driveshaft from the transmission. Support the end of the driveshaft using wire or string - do not allow the driveshaft to hang down under its own weight, or the joint may be damaged. 31 Unscrew the three securing bolts and remove the upper alternator mounting bracket
Starting and charging systems SA-S
=----!~ (119; . ..---. ---- . --/~[
----
\
6.31 Remove the upper alternator mounting bracket (1) - 1.4 and 1.6 litre DOHC engines
(see illustration). Note the location of the earth strap secured by the mounting bracket bolts. 32 Remove the nut and through-bolt securing the alternator to the lower mounting bracket. Recover any washers and insulating
A
bushes, noting their locations. 33 Support the alternator, and unbolt the lower mounting bracket from the cylinder block (see illustration). Withdraw the lower mounting bracket to allow sufficient clearance to remove the alternator.
B
34 Manipulate the driveshaft as necessary to allow sufficient clearance for the alternator to pass out through the wheelarch, then withdraw the alternator .
Refitting
35 Refitting is a reversal of removal , bearing in mind the following points: a) Refit the nut and through-bolt securing
the alternator to the lower mounting bracket before bolting the mounting bracket to the cylinder block. Ensure that any washers and insulating bushes are positioned as noted before removal.
b) Ensure that the earth strap is in position when refitting the upper alternator mounting bracket.
c) Reconnect the driveshaft to the front swivel hub assembly as described in Chapter 8.
d) Refit the auxiliary drivebelt as described in Chapter 1.
7 Alternator brushes and ~ regulator - inspection and ~ renewal ~
Standard Bosch alternator 1 The brush holder and voltage regulator are combined in a single assembly, which is bolted to the rear of the alternator (see
H28(53
6.33 Unbolt the alternator lower mounting bracket from the cylinder block - 1.4 and 1.6 litre DOHC engines
A Models without power steering or air conditioning B Models with power steering and/or air conditioning 1 Alternator lower mounting bracket
5A.6 Starting and charging systems
1 Pulley nut 2 Pulley 3 Fan 4 Drive end housing 5 Bearing 6 Bearing retainer 7 Through-bolts 8 Brush
holder/voltage regulator assembly
9 Slip ring end housing
10 Stator endplate 11 Stator 12 Bearing 13 Rotor
7.1 Exploded view of the standard Bosch alternator
illustration}. If the voltage regulator is faulty, the complete assembly must be renewed. 2 Disconnect the battery negative terminal
7.4a Remove the securing screws ...
7.5 Measuring the length of an alternator brush - standard Bosch alternator
(refer to Disconnecting the battery in the Reference Chapter). 3 If desired, to improve access further, the
7.4b ... and withdraw the brush holder! voltage regulator - standard Bosch alternator
7.10 Alternator slip rings (arrowed)standard Bosch alternator
alternator can be removed , as described in Section 6. 4 Remove the two securing screws, and withdraw the brush holder/voltage regulator assembly (see illustrations). 5 Check that the brushes move freely in their guides, and that the brush lengths are within the limits given in the Specifications (see illustration). If any doubt exists regarding the condition of the brushes, the best policy is to renew them as follows. 6 Hold the brush wire with a suitable pair of pliers, and unsolder it from the brush holder. Lift away the brush. Repeat for the remaining brush. 7 Note that whenever new brushes are fitted, new brush springs should also be fitted. 8 With the new springs fitted to the brush holder, insert the new brushes, and check that they move freely in their guides. If they bind, polish them lightly with a very fine file or glass paper. 9 Solder the brush wire ends to the brush holder, taking care not to allow solder to pass to the stranded wire. 10 Check the condition of the slip rings, and if necessary clean them with a rag or very fine glass paper (see illustration). 11 Refit the brush holder/ voltage regulator assembly, and tighten the securing screws. 12 If the alternator was removed, refit it as described in Section 6. 13 Reconnect the battery negative lead.
1 Pulley nut 2 Washer 3 Pulley 4 Bolt 5 Spacer 6 Drive end housing 7 Bearing 8 Bearing cover 9 Rotor
10 Bearing 11 Dust cover 12 Through-bolt 13 Plastic cover 14 Bolt 15 Voltage
regulator/brush holder 16 Bolt 17 Nut 18 Through-bolt 19 Rectifier 20 Slip ring end housing 21 Bush 22 Stator
Starting and charging systems SA-?
7.14 Exploded view of the compact Bosch alternator
Compact Bosch alternator 14 The brush holder and voltage regulator are combined as a single assembly (see illustration) . With the alternator removed as described in Section 6, proceed as follows. 15 Remove the three securing nuts, and withdraw the plastic cover from the rear of the alternator (see illustrations) . Note that it is possible that the studs may be withdrawn as the nuts are unscrewed - in this case, the studs can be refitted using two nuts locked together on the studs. 16 Remove the two securing screws, and withdraw the brush holder/voltage regulator assembly from the rear of the alternator (see illustrations). 17 Check that the brushes move freely in their guides, and that the brush lengths are within the limits given in the Specifications. If any doubt exists regarding the condition of the brushes, the complete brush holder/voltage regulator assembly must be renewed. 18 Refitting is a reversal of removal. 19 Refit the alternator as described in Section 6.
Standard De/co-Remy alternator Note: No spare parts are available for DelcoRemy alternators marked 'Made in Korea '. 20 The brush holder and voltage regulator
7.15a Unscrew the securing nuts .. .
7.16a Remove the securing screws . ..
7.15b . .. and withdraw the plastic cover -compact Bosch alternator
7.16b ... and withdraw the brush holder/ voltage regulator - compact Bosch alternator
5A.a Starting and charging systems
1 Pulley nut (not fitted to all models)
2 Pulley 3 Fan 4 Drive end housing 5 Bearing 6 Bearing retainer 7 Rotor 8 Through-bolt 9 Slip ring end housing
10 Brush holder/voltage regulator assembly
11 Diode assembly 12 Stator
7.20 Exploded view of the standard Delco-Remy alternator
are combined in a sing le assembly (see illustration). For access to the assembly, the alternator must be partially dismantled as follows. If the voltage regulator is faulty , the complete assembly must be renewed. 21 Remove the alternator as described in Section 6. 22 Scribe a line across the drive end housing and the slip ring end housing, to ensure correct alignment when reassembling. 23 Unscrew the three through-bolts, and prise the drive end housing and rotor away from the slip ring end housing and stator (see illustration). 24 Check the condition of the slip rings, and if necessary clean them with a rag or' very fine glass paper (see illustration), 25 Remove the three nuts and washers
7.23 Separating the drive end housing from the slip ring end housing - standard
Delco-Remy alternator
securing the stator leads to the rectifier, and lift away the stator assembly (see illustration) , 26 Remove the terminal screw, and lift out the diode assembly. 27 Extract the two screws securing the brush holder and voltage regulator to the slip ring end housing, and remove the brush holder assembly, Note the insulation washers under the screw heads. 28 Check that the brushes move freely in their guides, and that the brush lengths are within the limits given in the Specifications. If any doubt exists regarding the condition of the brushes, the best policy is to renew them. 29 To fit new brushes, unsolder the old brush leads from the brush holder, and solder on the new leads in exactly the same place.
7.24 Alternator slip rings (arrowed) -standard Delco-Remy alternator
30 Check that the new brushes move freely in the guides. 31 Before refitting the brush holder assembly, retain the brushes in the retracted position using a stiff piece of wire or a twist drill. 32 Refit the brush holder assembly so that the wire or drill protrudes through the slot in the slip ring end housing, and tighten the securing screws, 33 Refit the diode assembly and the stator assembly to the housing, ensuring that the stator leads are in their correct positions, and refit the terminal screw and nuts, 34 Assemble the drive end housing and rotor to the slip ring end housing, ensuring that the previously-made marks are still aligned. Insert and tighten the three through-bolts,
7.25 Stator lead securing nuts (A) and brush holder/voltage regulator securing
screws (8) - standard Delco-Remy alternator
7.35 Removing the drill bit used to hold brushes in retracted position - standard
Delco-Remy alternator
35 Pull the wire or drill (as applicable) from the slot in the slip ring end housing, so that the brushes rest on the rotor slip rings (see illustration). 36 Refit the alternator as described in Section 6.
Compact De/co-Remy alternator 37 With the alternator removed as described in Section 6, proceed as follows (see illustration). 38 Unscrew the securing nuts, 'and remove the plastic cover from the rear of the alternator . 39 Unscrew the two brush holder securing screws, noting their different lengths. Note that one of the screws also secures the suppressor (see illustration). 40 Unscrew the remaining suppressor securing nut, and lift the suppressor from the rear of the alternator. 41 Using a small screwdriver, or a similar tool , prise up the securing tag at the side of the brush holder, then lift the assembly from the rear of the alternator (see illustration) . 42 Check that the brushes move freely in their guides, and that the brush lengths are within the limits given in the Specifications. If any doubt exists regarding the condition of the brushes, the best policy is to renew them. If the brushes are renewed, it is wise to renew the brush springs at the same time.
Starting and charging systems 5A-9
7.37 Sectional view of the compact Delco-Remy alternator
1 Drive end housing 2 Stator
3 Rotor 4 Slip rings
43 To fit new brushes, unsolder the old brush ) leads from the brush holder, and solder on the new leads in exactly the same place, 44 Check that the new brushes move freely in the guides. 45 Refitting is a reversal of removal. 46 Refit the alternator as described in Section 6.
I
8 Starting system - testing ~
~ ~
Note: Refer to the precautions given in 'Safety first!' and in Section 1 of this Chapter before starting work.
5 Fan 6 Rectifier
If the starter motor fails to operate when the ignition key is turned to the appropriate position, the possible causes are as follows: a) The battery is faulty. b) The electrical connections between the
switch, solenoid, battery and starter motor are somewhere failing to pass the necessary current from the battery through the starter to earth.
c) The solenoid is faulty. , d) The starter motor is mechanically or
electrically defective. 2 To check the battery, switch on the headlights. If they dim after a few seconds, this indicates that the battery is discharged - recharge (see Section 3) or renew the battery. If the headlights glow brightly, operate the starter switch while
7.39 Brush holder securing screws (1) and suppressor (2)compact Delco-Remy alternator
7.41 Withdraw the brush holder (1) by after releasing the securing tag (2) - compact Delco-Remy alternator
5A-10 Starting and charging systems
9.3 Starter motor wiring securing nut (arrowed) - viewed from underneath
vehicle
watching the headlights. If they dim, then this indicates that current is reaching the starter motor, therefore the fault must lie in the starter motor. If the lights continue to glow brightly (and no clicking sound can be heard from the starter motor solenoid), this indicates that there is a fault in the circuit or solenoid - see the following paragraphs. If the starter motor turns slowly when operated, but the battery is in good condition , then this indicates either that the starter motor is faulty, or there is considerable resistance somewhere in the circuit. 3 If a fault in the circuit is suspected, disconnect the battery leads (including the earth connection to the body) , the starter/solenoid wiring and the engine/ transmission earth strap. Thoroughly clean the connections, and reconnect the leads and wiring. Use a voltmeter or test light to check that full battery voltage is available at the battery positive lead connection to the solenoid . Smear petroleurn jelly around the battery terminals to prevent corrosion -corroded connections are among the most
frequent causes of electrical system faults. 4 If the battery and all connections are in good condition , check the circuit by disconnecting the switched feed wire from the solenoid (the thinner wire). Connect a voltrneter or test light between the wire end and a good earth (such as the battery negative terminal), and check that the wire is live when the ignition switch is turned to the 'start' position. If it is, then the circuit is sound - if not, there is a fault in the ignition/starter switch or wiring. 5 The solenoid contacts can be checked by connecting a voltmeter or test light between the battery positive feed connection on the starter side of the solenoid, and earth . When the ignition switch is turned to the 'start ' position, there should be a reading or lighted bulb, as applicable. If there is no reading or lighted bulb, the solenoid is faulty and should be renewed. 6 If the circuit and solenoid are proved sound, the fault must lie in the starter motor. Begin checking the starter motor by removing it (see Section 9), and checking the brushes (see Section 10). If the fault does not lie in the brushes, the rnotor windings must be faulty. In this event, the starter motor must be renewed, unless an auto-electrical specialist can be found who will overhaul the unit at a cost significantly less than that of a new or exchange starter motor.
9 Starter motor -removal and refitting
Removal 1 Disconnect the battery negative terrninal
(refer to Disconnecting the battery in the Reference Chapter). 2 Apply the hand brake, then jack up the front of the vehic le, and support securely on axle stands (see Jacking and vehicle support). 3 Note the wiring connections on the solenoid, then unscrew the securing nuts (where applicable) and disconnect them (see illustration). 4 Where applicable, unscrew nut securing the earth cable to the upper starter motor mounting stud. Recover the washer, and disconnect the cable from the stud. 5 On 1.0 and 1.2 litre DOHC engines unbolt the inlet manifold support bracket from the rnanifold and cylinder block. 6 Unscrew the starter motor rnounting stud and bolt, or the two bolts, as applicable, and withdraw the motor from under the vehicle.
Refitting 7 Refitting is a reversal of removal, but where applicable, ensure that the earth cable is reconnected to the stud.
10 Starter motorbrush renewal
De/co-Remy starter motor 1 With the starter motor rernoved from the vehicle as described in Section 9 and cleaned, grip the unit in a vice fitted with soft jaw protectors (see illustration). 2 Make alignment marks between the main motor casing and the commutator end housing. 3 Unscrew' and remove the two through-bolts
/
1 Solenoid yolk 2 Solenoid return spring 3 Solenoid armature 4 Actuating arm 5 Pivot pin clip 6 Drive end housing 7 Actuating arm pivot pin 8Shim 9C-c/ip
10 Thrust collar ,-11 Drive pinion and clutch assembly 12 Armature 13 Main motor casing 14 Through-bolt 15 Commutator end housing 16 Brush plate 17 Field coils 18 Permanent magnet
10.1 Exploded view of the Delco-Remy starter motor
10.3 Unscrew the through-bolts . ..
which hold the components of the starter motor assembly together (see illustration). 4 Extract the two small screws which secure the commutator end housing to the brush plate, then lift off the commutator end housing (see illustration). 5 Lift the brush retaining springs to remove the field brushes from the brush holders, then lift the brush plate from the commutator (see illustration). 6 Remove the remaining springs and brushes from the brush holder. 7 If the brushes have worn to less than the specified minimum length, renew them as a set. To renew the brushes, the leads must be unsoldered from their terminals, and the new brushes must be soldered in place. 8 Clean the brush holder assembly, and wipe the commutator with a petrol-moistened cloth. If the commutator is dirty, it may be
10.17 Removing the rear cover - Valeo starter motor
10.19a Lift the negative brush terminal from the stud . ..
Starting and charging systems 5A.11
10.4 . . . and extract the two small screws - Delco-Remy starter motor
cleaned with fine glass paper, then wiped with the cloth. 9 Check that the brush retaining springs provide adequate pressure on the brushes to maintain good contact with the commutator. Renew any worn springs. 10 Refit the brushes to the brush holder, and refit the retaining springs. To aid refitting of the brush holder assembly, the brushes can be retained in position using a socket or suitable tube of approximately 38.0 mm diameter. 11 Slide the brush holder over the commutator and, where applicable, withdraw the socket or tube. 12 Fit the commutator end housing, ensuring that the marks made on the end housing and the main motor casing are aligned. 13 Fit the two screws securing the end housing to the brush plate. 14 Refit and tighten the two through-bolts.
10.18a Lever the brush spring from the brush plate . ..
10.19b ... and the positive brush terminal (arrowed) from the insulator -
Valeo starter motor
10.5 Lift the brush plate from the commutator - Delco-Remy starter motor
15 Refit the starter motor as described in Section 9.
Va/eo starter motor 16 With the starter motor removed from the vehicle as described in Section 9 and cleaned, proceed as follows. 17 Unscrew the two securing nuts, and withdraw the rear cover from the starter motor (see illustration). 18 Using a suitable screwdriver, lever the brush spring from the brush plate . Recover the insulator plates from under the ends of the spring (see illustrations). 19 Lift the negative brush wiring terminal from the stud on the brush plate, and lift the positive brush terminal from the insulator in the motor body (see illustrations). 20 Lift the brushes from the brush plate. Note the locations of the brushes to ensure correct reassembly (see illustration).
10.18b ... and recover the insulator plates - Valeo starter motor
10.20 Lifting a brush from the brush plate - Valeo starter motor
5A-12 Starting and charging systems
10.23 Remove the brush plate to enable cleaning of the commutator (arrowed) -
Valeo starter motor
21 If the brushes have worn to less than the minimum specified length, they must be renewed. 22 If the positive brush is to be renewed, it must be unsoldered from the terminal on the solenoid wiring. 23 If desired, the brush plate can be lifted from the motor to enable the commutator to be cleaned (see illustration). Clean the brush plate assembly, and wipe the commutator with a petrol-moistened cloth . If the commutator is very dirty, it may be cleaned with fine glass paper, then wiped with the cloth.
12.1 a Oil pressure warning light switch location (arrowed) - SOHC engines, and
1.4 and 1.6 litre DOHC engines
10.27 Refitting the brush spring - Valeo starter motor
24 Check that the brush retaining spring provides adequate pressure on the brushes to maintain good contact with the commutator. Renew the spring if it is worn . 25 Commence refitting by refitting the brush plate (where applicable), and placing the brushes in position in the brush plate. 26 Locate the negative brush wiring terminal over the stud on the brush plate, and locate the positive brush terminal in the insulator in the motor body. 27 Fit the insulator plates to the ends of the brushes, then fit the brush spring (see illustration) .
12.1 b Oil pressure warning light switch location (arrowed) - 1.0 and 1.2 litre
DOHC engines
28 Ensure that the insulator is in place in the wiring grommet cut-out in the motor rear cover, then refit the cover to the motor. 29 Refit the rear cover securing nuts. 30 Refit the starter motor as described in Section 9.
11 Ignition switch - . removal and refitting
The switch is integral with the steering column lock, and removal and refitting is described in Chapter 10.
12 Oil pressure warning light ~ switch - -removal and refitting ~
~
Removal 1 On SOHC engines, and 1.4 and 1.6 litre DOHC engines, the switch is screwed into the end of the oil pump, on the inlet manifold side of the engine (see illustration). Access is most easily obtained from underneath the vehicle. On 1.0 and 1.2 litre DOHC engines, the switch is screwed into the front right-hand side of the cylinder head (see illustration). 2 Disconnect the battery negative terminal (refer to Disconnecting the battery in the Reference Chapter). 3 Disconnect the wiring from the switch. 4 Place a suitable container under the switch, to catch the oil which will be released as the switch is removed. 5 Using a suitable spanner, unscrew the switch . Be prepared for oil spillage, and plug the hole in the oil pump immediately, to minimise oil loss and prevent dirt ingress.
Refitting 6 Refitting is a reversal of removal. On completion, check and if necessary top-up the engine oil level as described in Weekly checks.
