Removal and installation of the voltage regulator
1. Remove the generator (see Section 10).
2. Loosen 2 nuts, remove the screw and remove the protective cover from the generator (see resist. illustration).
11.2 Nuts (1) and screw securing the protective cover of the generator
3. Remove 3 bolts (see resist. illustration) and remove the voltage regulator from the alternator. Remove and replace brushes if necessary
11.3 Regulator (4) tension 3 Mounting bolts: 5. Generator brushes; 6. Protective cover
4. Installation is carried out in the reverse order.
Features of the Y30DT engine
5. Remove generator
6. Clamp the generator in a vise, remove the 3 bolts and remove the heat shield from the generator.
7. Remove the front air duct from the generator. Turn out a fixing bolt, release 2 nuts of fastening of the back air channel/protective cover of the generator.
8. Carefully disconnect the intermediate element of the air channel, unscrew the 3 bolts and remove the voltage regulator.
Checking and replacing the generator brushes
9. Remove the voltage regulator (see above) and check the length of the brushes. The brushes must be replaced if they protrude from the brush holder by 5 mm or less, or if the difference in brush length is more than 1 mm. Unsolder wires if necessary and remove worn brushes.
10. Check the slip rings for wear, grind and polish them if necessary - contact an Opel workshop.
12. Clean the contact surfaces, check the spring stiffness, replace if necessary.
13. Insert new brushes with springs into the brush holder (see resist. illustration) and solder electrical wires.
11.13 Installing the brushes (A) into the brush holder (WITH): B. Brush springs
Note: When soldering, the brushes must be held by the wires with pliers to avoid solder directly on the brushes, otherwise they become hard and unusable.
14. Install the voltage regulator and secure it.
15. After installation, check the ease of movement of the brushes in the brush holder.
16. Further installation is carried out in the reverse order of removal.
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