Generator Brushes (Delco-Remy Type) — Checking, Removing and Installing (Opel Ascona C)

1. Disconnect the generator from the engine as described in Section 8.

2. Scratch a line through the stator housing and front end cover to ensure proper installation later.

3. Loosen and remove the three through-mount bolts, then remove the front cover with rotor from the rear end housing and stator. Check the condition of the removable rings, they may need cleaning with a cloth soaked in gasoline or very soft sandpaper (see photo 10.3 A and B).





4. Unscrew the three nuts and washers securing the stator wires to the rectifier and remove the entire stator structure, then unscrew the contact screw and remove the diode bracket (see photo 10.4).





5. Remove the two screws securing the brush holder and voltage regulator to the rear end casing and remove the entire brush holder assembly. Note that there are insulating washers located under the screw heads.

6. Check that the brushes can move freely in their guides and that their length complies with the limits specified in the Specifications. If there is the slightest doubt about the condition of the brushes, it is best to replace them with new ones.

7. To install new brushes, first unsolder the wires of the old brushes from the holder, and then solder the wires of the new brushes in exactly the same place.

8. Check that the new brushes can move freely in their guides.

9. Before installing the brush holder, hold the brushes in the retracted position using a piece of stiff wire or a small Allen key.

10. Install the brush holder so that the wire protrudes through the slot in the rear casing as shown (see photo 10.10).





11. Install the diode bracket and stator into the housing, making sure the stator wires are in the correct position.

12. Assemble the front casing and rotor together with the stator casing, aligning the previously made marks. Insert the three through-mount bolts and tighten them.

13. Now carefully pull the piece of wire out of the slot in the rear casing so that the brushes can reach the removable rotor rings.

14. Now the generator can be installed back on the car and its operation can be checked.

15. It should be remembered that if the generator is replaced with a new or repaired one, then you will need the fan and pulley from the old generator. To release the pulley nut, hold the rotor shaft with an Allen key while the nut is being loosened (see photo 10.15).