charging problems.

[chrisfnq]

Here is the story.
noticed a about a month ago charge on the meter was high. checked with multimeter and alt. was pumping out 16.7 volts.
couldnt get into see my normal auto elect. so after phone call have been driving with ac and lights on to drop volts.
Was running ok... on thursday (just after all the shops close for easter..lol) my dash lights up like a christmas tree.
So alt. now failing to charge. meter on dash is showing 12 volts..( bat voltage)
I manage to source a new alt. and just fitted.. but is showing no charge.
Any ideas as to what i missed?
It was a new alt. not a overhauled/recond.
I have checked in the engine bay the main fuses, charge relay and diode in the box... all appear to be ok.
Thanks for any ideas.
Chris

[muzila]

There is 2 lots of wiring looms that run along the engine on the passangers side.

1 runs down by the sump and the other runs under the intake manifold behind the fuel pump. Check both of them for wire damage.

I had same problem and found wires damaged in the second loom i mentioned.

Don't no if it will sort you out but won't hurt to check them.

[muzila]

I would also replace the charge relay with a new one if you havn't already done so as they usually pop when the alt goes legs up.

[chrisfnq]

tested relay, on bench and functions ok.
i tried to follow wires from alt to fuse box and from fuse box i am lost... lol.
has anyone got a wiring diagram or can identify which wire goes to where?
i have four wires from alternator. battery wire( large white)
and three smaller wires from connector on back of alt.
any help would be great...sorry muzila but my wire looms run down driver side... and i havent been able to find any damaged... thinking tomorrow i pull out relay box to see if i can find any fault. ( small night mare..)
thanks
chris

[muzila]

Trust me you don't want to pull the relay/fuse box out and look under there if thats the one you mean if you can help it. Its a total confusing mess under there, if I had my camera here I would take a foto to show you. lol.

The looms I talking about are not easy to see. but they are on the passengers side and both prone to damage. I will take fotos of them 2morrow when I get my camera back and put them up for you to see. I show you the fuse box underneith as well. lol.

[geeves]

How did you test the relay? this relay triggers on voltage and current.
The failure you describe is a common failure. The regulator fails going high voltage which burns out the stator which goes high current which a short time later burns out the relay. Shouldnt be other problems

[chrisfnq]

i got the sparky at work to test the relay, he made up some test leads and connected it to a 12 volt battery and got it to function... it was not an original relay, so it had a diagram on it to follow each contact. he says the relay is healthy.. i will fit new on tomorrow reguardless. ok muzilla... i will try to find the looms...i opened the fuse box... i think it would be easier to follow cooked spagetti..lol i got it back together...lol
thanks for your help.
chris

[muzila]

Yea its not nice in there ae. My camera not home yet so I havn't got fotos for you yet sorry. I will take them when it finds its way home.

I suspect when you replace the charge relay with a new proper one. (its blue) then it will hopefully work.

[chrisfnq]

i have given up...lol.. tomorrow i am in at auto elecs...lol they are finally back from easter holidays..... wish i got half the time off they have had.. i hope its a quick fix for them.. thanks again for your help.

[chrisfnq]

problem all fixed..lol
fault internally on a brand new alternator.. a broken wire connecting the regulator. i took 3 hours for the auto elec to fault find even with a background story... now the fun of trying to get blood from a stone... or a refund from a spare parts dealer. lol... thanks muzilla and geeves for the help.
all the best
chris

[geeves]

With the price of the alternator Definatly get a refund. The report from the auto sparky will help. Start nicly but remember your consumer protection laws and small claims court if you have too.
Did you fix that alternator or get anouther new one?

[chrisfnq]

had the new one fixed. the auto elec didnt want to stuff me around..., went to try for refund..the process is started.. they are now contacting the supplier/manufacturer of the alternator to get them to try and pay up... the spare parts shop was very helpful.

[muzila]

Dam ae. A faulty new alt. who would of guessed that one. At least its fixd for you now.

Good luck with the refund.

[chrisfnq]

had a few of us stumped... the sparky at work was happy when i told him..lol he had been pulling hair trying to nut this one out...
if i didnt like the mu.. would have almost traded it..lol..
it is not the same as the numbers on the faq..so later i will post as still got the box it came in.. i am happy now... working shift and driving all over the place isnt nice when you think you are cooking the battery or not going to start again..lol
is my second alternator in 9 years.