Alternator — replacement

This section describes how to remove two different alternators from the Astra and Zafira models. On vehicles, depending on the configuration and year of manufacture, various models of generators may be installed, the performance of operations on which may vary slightly. However, using generalized information on these generators, you can perform similar operations on any generator installed specifically on your car.

To perform the work, an inspection ditch or overpass is required.

Replacing the alternator on Astra models with a 1.6 DOHC engine manufactured after 2000

1. We prepare the car for work (see «Preparing the car for maintenance and repair»).

2. Remove the accessory drive belt (see «Accessory drive belt - condition check and replacement»).

3. Using a 13 mm wrench, unscrew nut 1 and remove the wire from the B+ terminal of the generator, and unscrew nut 2 with an 8 mm wrench and remove the wire from the L generator output.



4. Using a 13 mm wrench, unscrew the bolt securing the holder for the wiring harness pads.



5. Using the E14 TORX key, we unscrew the bolts securing the upper bracket of the generator to the generator, the intake receiver...




...to the block head...



...and remove the bracket.



6. With a TORX E14 key, we hold the bolt from turning, and with a 16 mm key we loosen the nut of the lower generator mount (shown on removed assembly)...



...and remove the generator.




7. We install the parts in the reverse order.

Replacing the alternator on a Zafira model with a 1.8 DOHC engine manufactured before 2000.

1. We prepare the car for work (see «Preparing the car for maintenance and repair»).

2. Remove the accessory drive belt (see «Accessory drive belt - condition check and replacement») and its tensioner (see «Accessory Drive Belt - Tensioner Replacement»).

3. Using an 8 mm wrench, unscrew the nut...



... and remove the wire from the output L of the generator.



4. With a 13 mm wrench, unscrew the nut...




...and remove the wire from the B+ terminal of the generator.



5. With a 13 mm wrench, unscrew the nut...



...and detach the tip «mass» wires.



6. With the same key, turn out the pin.




7. Using the TORX E14 key, we unscrew the bolts securing the upper bracket to the generator...



... and to the block head and remove the bracket.



8. With a TORX E14 key, we hold the bolt from turning, and with a 16 mm key, we loosen the nut of the lower mounting of the generator (shown on removed assembly).



9. Using the TORX -E14 key, unscrew the three bolts securing the bottom bracket...



... and remove the generator assembly with the bottom bracket.



10. Finally unscrew the nut, remove the bolt and disconnect the generator from the bracket.

11. We install the parts in the reverse order.