Starting And Charging Systems - Opel Zafira B MPV 2006 Owners Workshop Manual

Chapter 5 Part A:
Starting and charging systems
Contents
Section number
Alternator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Alternator - testing and overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Auxiliary drivebelt - removal and refitting. . . . . . . . . . . . . . . . . . . . . . 6
Auxiliary drivebelt tensioner - removal and refitting. . . . . . . . . . . . . . 7
Battery and battery tray - removal and refitting. . . . . . . . . . . . . . . . 4
Battery - testing and charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery check .............................. See Weekly checks
Charging system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical fault finding - general information . . . . . . . . . . . . . . . . . . . 2
Electrical systems check ................... See Chapter 1 A or 1 B
General information, precautions and battery disconnection . . . . . . 1
Degrees of difficulty
Section number
Glow plugs (diesel engine models) - removal, inspection and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ignition switch - removal and refitting ........................ 13
Oil level sensor - removal and refitting ........................ 15
Oil pressure warning light switch - removal and refitting .......... 14
Pre/post-heating system (diesel engine models) - description and
testing ............................................... 16
Pre/post-heating system control unit (diesel engine models) - removal
and refitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Starter motor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 11
Starter motor - testing and overhaul ......................... 12
Starting system - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Easy, suitable for
novice with little
experience
~
I
Fairly easy, suitable
~
I
~
for beginne~ with
~
~
some experience "
Fair1y difficult,
~
I
Difficult, suitable
~
I
Very difficult,
suitable for competent~ for experienced DIY
~
suitable for expert
DIY mechanic " mechanic " DIY or professional
Specifications
General
Electrical system type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt negative earth
Battery
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lead-acid, 'maintenance-free' (sealed for life)
Charge condition:
Poor ................................................. .
Normal ............................................... .
Good ................................................ .
Torque wrench settings
Petrol engine models
Alternator:
Alternator mounting bolts (2.2 litre engines) ........... .
Alternator to mounting bracket (1.6 and 1.8 litre engines) ........ .
Auxiliary drivebelt tensioner:
1.6 and 1.8 litre engines .................................. .
2.2 litre engines ........................................ .
Oil level sensor:
1.6 and 1.8 litre engines .................................. .
2.2 litre engines ........................................ .
Oil pressure warning light switch:
1.6 and 1.8 litre engines .................................. .
2.2 litre engines ........................................ .
Roadwheel bolts .......................................... .
Starter motor:
1 .6 and 1 .8 litre engines:
Intake manifold support bracket bolts ..................... .
Starter motor mounting bolts . . . . . . . . . ................. .
2.2 litre engines:
Starter motor mounting bolts ............................ .
Diesel engine models
Alternator mounting bolts ................................... .
Auxiliary drivebelt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .
Glow plugs ............................................. .
Oil pressure warning light switch . . . . . . . . . . . . . . . . . . . . ........ .
Roadwheel bolts .......................................... .
Starter motor mounting bolts ................................ .
12.5 volts
12.6 volts
12.7 volts
Nm
lbf ft
20
15
35
26
50
37
43
32
8 6
10
7
20
15
18
13
110
81
8
6
25
18
40
30
70
52
50
37
8
6
25
18
110
81
25
18