Battery Disconnection; Charging; Traditional And Low Maintenance Battery; Maintenance-Free Battery - Opel Zafira B MPV 2006 Owners Workshop Manual

5A•2 Starting and charging systems
1 . t~n~rattnformationi
sand
disc9nnect1on
General information
The engine electrical system consists mainly
of the charging and starting systems and
the diesel engine pre/post-heating sy~tem.
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). On petrol engine models refer to
Part B for information on the ignition system.
The electrical system is of 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 the
crankshaft pulley.
. The sta~er m?tor is of pre-engaged type
1ncorporat1n_g an integral solenoid. On starting,
the solenoid moves the drive pinion into
engagement with the flywheel/driveplate ring
gear before the starter motor is energised.
Once the engine has started, a one-way clutch
prevent~ the motor armature being driven by
the engine until the pinion disengages.
. Further details of the various systems are
g1v~n
in
the relevant Sections of this Chapter.
While some repair procedures are given,
the usual course of action is to renew the
component concerned.
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 injuty. In addition to the precautions
given in Safety first! at the beginning of this
manual, observe the following when working
on the system:
• Al"':ays 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.
3.5 Battery charge condition indicator -
'Delco' type battery
Components such as the alternator, electronic
control units, or any other components having
semi-conductor circuitry could be irreparably
damaged.
" If the engine is being started using jump
leads and a slave battery, connect the
batteries positive-to-positive and negative-to-
negative (see Jump starting). This also applies
when connecting a battery charger but in this
case both of the battery terminals should first
be disconnected.
• 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
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 fuel injection/
ignition electronic control unit to protect them
from the risk of damage.
Battery disconnection
Refer to the precautions shown in Disc-
onnecting the battery in the Reference
Chapter.
2 Electrical fault finding -
general Information
Refer to Chapter 12.
3 Battery-
testing and charging
Testing
Traditional and
low maintenance battery
1 If the vehicle covers a small annual mileage,
it is worthwhile checking the specific gravity
of the electrolyte every three months to
determine the state of charge of the battery.
Use a hydrometer to make the check and
compare the results with the following table.
Note that the specific gravity readings assume
an electrolyte temperature of 15°C; for every
10°C below 15°C subtract 0.007. For every
10°C above 15°C add 0.007.
Ambient temperature
above below
25°C 25°C
Fully-charged 1.210 to 1.230 1.270 to 1.290
70% charged 1.170 to 1.190 1:230 to 1.250
Discharged 1.050to 1.070 1.110to 1.130
2 If the battery condition is suspect, first check
the specific gravity of electrolyte in each cell.
A variation of 0.040 or more between any cells
indicates loss of electrolyte or deterioration of
the internal plates.
3 If the specific gravity variation is 0.040 or
more, the battery should be renewed. If the
cell variation is satisfactory but the battery is
discharged, it should be charged as described
later in this Section.
Maintenance-free battery
4 Where a 'sealed for life' maintenance-free
battery is fitted, topping-up and testing of the
electrolyte in each cell is not possible. The
condition of the battery can therefore only be
tested using a battery condition indicator or a
voltmeter.
5 Some models are fitted with a
maintenance-free battery with a built-in
'magic-eye' charge condition indicator. The
indicator is located in the top of the battery
casing, and indicates the condition of the
battery from its colour (see illustration). If
the indicator shows green, then 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.
All battery types
6 If testing the battery using a voltmeter,
connect the voltmeter across the battery
and compare the result with those given in
the Specifications under 'charge condition'.
The test is only accurate if the battery has
not been subjected to any kind of charge for
the previous six hours. If this is not the case,
switch on the headlights for 30 seconds, then
wait four to five minutes before testing the
battery after switching off the headlights. All
other electrical circuits must be switched off,
so check that the doors and tailgate are fully
shut when making the test.
7 If the voltage reading is less than 12.2 volts,
then the battery is discharged, whilst a reading
of 12.2 to 12.4 volts indicates a partially-
discharged condition.
8 If the battery is to be charged, remove it
from the vehicle (Section 4) and charge it as
described later in this Section.
Charging
Note: The following is intended as a guide
only. Always refer to the manufacturer's
recommendations (often printed on a label
attached to the battery) before charging a
battery.
Traditional and
low maintenance battery
9 Charge the battery at a rate of 3.5 to 4 amps
and continue to charge the battery at this rate
until no further rise in specific gravity is noted
over a four hour period.