Starter design

Want to hear a funny expression? Here it is: «starter with progressive screw drive». It is installed in the Vectra and functions as follows:

• When the ignition key is turned to position «Start» voltage (from the ignition switch) enters terminal 50 of the electromagnetic switch located at the top of the starter.
• As a result of this, the starter lever shifts the starter gear along a steep thread into the ring gear of the engine flywheel.
• When the gear is engaged, the electromagnetic switch turns on the full battery current from terminal 30, and only after the gear engages does the starter crank the engine powerfully.
• If the engine starts, the gear comes out of the flywheel again.

Types of starters

The Vectra has either a Bosch or Valeo starter. By design, these starters do not differ from each other. Both starters have a power of 1.4 kW.

Starter removal

Disconnect the ground wire on the battery, otherwise there will be a danger of a short circuit.

Where present, unscrew the intake manifold support from the intake manifold and from the engine block.

If there is, unscrew the starter support.

Unscrew the positive battery cable and terminal 50 wire from the magnetic switch.

Unscrew the top fixing bolt (long bolt) starter on the gearbox side.

Unscrew the lower fixing bolt and remove the starter.

When mounting, pay attention to the different lengths of the bolts.

Tighten the starter mounting bolts to 60 Nm.

Tighten the starter support to 25 Nm. Support on the intake manifold and on the engine - 20 Nm.

Replacement of graphite brushes

If the starter is on strike, then perhaps the graphite brushes have just worn out. These brushes can be bought at an Opel workshop or parts store and then replaced. Next you need: knowledge of soldering, electrical solder and a powerful soldering iron, at least 150 watts. If you do not have a soldering iron, then you can dismantle and mount the starter yourself, but solder the graphite brushes in a car repair shop. There you can check the starter for various electrical and mechanical functions.

Bosch Graphite Starter Brush Replacement

Unscrew the support from the starter.

Unscrew the bearing cover from the manifold support.

Remove the anchor washer and the compensation (s) puck (s) from the anchor shaft. Pay attention to the rubber ring.

Unscrew both screws of the pole housing.

Remove the manifold side bearing from the housing.

Remove the graphite brushes from the bracket and measure their length. The minimum length is 13 mm.

Unsolder the copper wire ends of the worn graphite brushes.

When soldering, grasp the ends of the stranded wire of the new brush with pliers to prevent the tin solder from flowing into the stranded wire.

Replacement of Valeo starter graphite brushes

Remove the starter.

Unscrew the wires to the starter from the electromagnetic switch.

On the closed side of the starter, unscrew both fastening nuts on the housing cover.

Remove the housing cover from the starter along with the gasket and graphite brushes.

Remove the carbon brush holder from the housing cover.

Depress the pressure spring from the brush holder with a screwdriver. At the same time, pay attention to the insulating plates.

Remove the insulating plates and graphite brushes from the brush holder.

Measure the length of the graphite brushes: min. 13 mm.

When installing, slide the brush holder with gasket onto the starter.

Insert the positive graphite brushes into the brush holder. Insert the elbow of the connecting core of the wire into the gasket guide.

Push the wire end onto the connector of the electromagnetic switch.


Insert a negative graphite brush into the brush holder.

Slide the tip of the negative graphite brush onto the left mounting bolt of the housing cover.

Apply insulating plates to the graphite brushes.

Apply the pressure spring and firmly press the spiral into the brush holder.

Install the insulated housing cover to the starter.

Slide the insulating sleeve over the connector of the positive graphite brush until it locks into place.

Screw the connecting wire on the magnetic switch.

Removing the electromagnetic switch

Remove the starter.

Unscrew the wire to the starter.

Unscrew the fixing bolts on the flange of the electro-magnetic switch.

Bosch starter: pull back the solenoid switch a little and unhook the lug from the starter lever.

Delco Remy starter: Loosen mounting bolts on magnetic switch mounting flange.

Remove the electromagnetic switch with a rotary motion from the starter.