Stabilizer and brushes — inspection and replacement (Opel Astra F)

Delco-Remy type generator (Fig. 12.3)

The brush holder and voltage regulator are combined into one unit. To access the assembly, the generator must be partially disassembled as shown below. If the voltage regulator is faulty, the entire unit must be replaced.

Remove the generator as described above.

Draw a line across the drive shaft end housing and the slip ring end housing to ensure proper alignment during assembly.

Remove the three through bolts and separate the shaft housing from the slip ring housing and stator.

Check the condition of the contact rings and, if necessary, remove dirt with a rag or very fine glass sandpaper.

After removing the three nuts and washers securing the stator wires, remove the stator assembly (Fig. 12.5).





Remove the screw and take out the diode block.

After removing the two screws securing the brush holder and voltage stabilizer to the contact track housing, remove the brush holder assembly.

Check that the brushes move freely in their guides and that the brush length is within the limits specified in the technical specifications.

To install new brushes, unsolder the ends of the holder connections and solder new wires.

Check that the new brushes move freely in the guides.

Before installing the brush holder assembly, push the brushes aside using a suitable tool.

Install the diode block and stator assembly.

Install the generator as described in the previous section.

Bosch type current generator (Fig. 12.4)

The brush holder and voltage stabilizer are combined in one unit, which is secured with bolts at the end of the generator. If the voltage stabilizer is faulty, the entire assembly must be replaced.

Disconnect the air lines from the air cleaner and air box or throttle body and where necessary to provide adequate access.

Disconnect the negative battery terminal.

Remove the two screws and take out the brush holder/voltage stabilizer assembly (Fig. 12.6).



Make sure that the brushes move freely in the guides and that the length of the brushes is within the limits specified in the technical specifications (Fig. 12.7).



If there is any doubt about the condition of the brushes, it is best to replace them as indicated below.



Clamp the brush wire with pliers and unsolder it. Remove the brush. Do the same with the other brushes.

After installing the new springs on the brush holder, insert the new brushes and make sure they move freely in the guides. If they stick, lightly polish them with a velvet file or fine glass paper.

Solder the ends of the brush wires to the brush holder.

Check the condition of the contact rings and, if necessary, remove dirt from them with a rag or very fine glass sandpaper.

Install the brush holder/voltage stabilizer assembly and tighten the screws.

Install the generator as described above.

Connect the negative battery terminal.

Install air ducts.