@Bushwhacker + electrical gurus

[Rustinho]

Hi there folks,

I'm away at the in-laws and am having problems with the batteries not charging.
The associated warning lights/constant beep are permanently on when the engine is running.

I've just had the alternator replaced with a used unit sent to me by Vince but I have suspicions about the procedure the garage went through when fitting it (the clocks didn't need re-setting when I got the Surf back so I think one battery might have been left connected when they switched the alternators over).

I initially suspected the fuse but that doesn't seem to be the problem.

If I start the engine and then remove the fuse the warning lights/beeps stop (as well as speedometer, rev counter, etc stopping working too).

Can someone please give me a few pointers as to what to do next, please?

I should be able to access some tools c/o my father in law such as multimeter, etc so I can do some basic tests & plan to check the fault codes (just in case) tomorrow once the batteries are re-charged.

Thanks in advance for any help offered, folks.

[TonyN]

Have you checked all the earth straps from block to chassis, both sides of the engine?

And obviously that they've actually connected all the alt wiring properly.

[BUSHWHACKER]

Is the ALT fuse OK? It's one of the big bolt-in fuses in the box under the bonnet.

[Vultch]

Voltmeter across a battery on tickover..then rev the engine the voltage should rise slightly i.e. 12v to 13. 4 as a guide..

[Rustinho]

Have you checked all the earth straps from block to chassis, both sides of the engine?

And obviously that they've actually connected all the alt wiring properly.

Earth straps from the negative terminals of both batteries seem sound enough, as does the earth to the body from the alternator. The alternator wiring feels ok (no loose connectors, etc).

Is there something else I need to be checking?

Is the ALT fuse OK? It's one of the big bolt-in fuses in the box under the bonnet.

It is obviously completing a circuit given the changes when it is removed (ie engine won't even try to turn over, removing the fuse after starting the engine stops the gauges working but doesn't stop the engine)

I tried to get a replacement from Halfords today but they didn't have anything close to being a replacement.

Voltmeter across a battery on tickover..then rev the engine the voltage should rise slightly i.e. 12v to 13. 4 as a guide..

Have to admit that I haven't tried this as yet but the voltmeter on the dashboard was registering an increase in voltage with revving immediately after the replacement alternator was fitted.

The problems have started in the couple of days since it was fitted and it is not registering a voltage increase on revving anymore (plus it's killed the batteries doing 150 miles today)

[BUSHWHACKER]

Is the (ign) fuse ok in the fuse box by the accelerator pedal?
Is the thick white wire (it goes to the battery via a connector block) on the side of the alternator secure?

The big square ALT fuses have been known to fracture due to age/vibration (I've seen two examples of this) and have a hairline crack that is difficult to spot causing charging issues due to an intermittant connection being made.

Obvious question time: Are the belts tight?

Some Toyota charging circuit info here that may help you...
http://www.autoshop101.com/forms/h8.pdf


If it's discovered that the alternator is fubarred, then I have another one here (round plug type) you can have if you cover postage.

[Rustinho]

Is the (ign) fuse ok in the fuse box by the accelerator pedal?
Is the thick white wire (it goes to the battery via a connector block) on the side of the alternator secure?

The big square ALT fuses have been known to fracture due to age/vibration (I've seen two examples of this) and have a hairline crack that is difficult to spot causing charging issues due to an intermittant connection being made.

Obvious question time: Are the belts tight?

Some Toyota charging circuit info here that may help you...
http://www.autoshop101.com/forms/h8.pdf


If it's discovered that the alternator is fubarred, then I have another one here (round plug type) you can have if you cover postage.

Hi there!

Just got my father-in-law checking out the alternator (he's an electronics engineer so knows his stuff).

We've been checking various bits & bobs and the thick white wire is giving 12v with the engine off, which drops to 11v when the engine is running so he reckons it's the alternator that isn't kicking anything out.

How much for postage?

[BUSHWHACKER]

Hi there!

Just got my father-in-law checking out the alternator (he's an electronics engineer so knows his stuff).

We've been checking various bits & bobs and the thick white wire is giving 12v with the engine off, which drops to 11v when the engine is running so he reckons it's the alternator that isn't kicking anything out.

How much for postage?

It was £14.96 last time.

My Xmas is now ruined as it appears I have sold you something thats obviously not fit for purpose.

[Rustinho]

It was £14.96 last time.

My Xmas is now ruined as it appears I have sold you something thats obviously not fit for purpose.

Actually - I'm only just up the road from you at the moment (Coleford in Gloucestershire, going to Stroud later today to stay with more in-laws) and will be all this week.

Might be as easy as anything for me to either pop over to you or meet somewhere if you're out and about anywhere near here in the next couple of days. You did say that you needed to get some miles in on a Lexurf the other day!

Internet access once I'm in Stroud will be next to zilch so I'll PM you my mobile number (unfortunately I don't get any mobile phone signal here so I won't be able to take any calls til this evening).

Cheers matey.

[Rustinho]

Righto. I'm in Stroud now with internet only available via WAP on my mobile phone! :-)

[BUSHWHACKER]

I'm at NP11 5JY. You're welcome to come over and we can fit the replacement alternator. Alternatively I'll box it up and get the missus to drop it off at the post office with my other sale items. I can't really leave the house this week as I've got deliveries and collections coming.

p.s. The Lexurf you're referring to is now in Belfast, see Lexurf VII thread.

[Rustinho]

I'm at NP11 5JY. You're welcome to come over and we can fit the replacement alternator. Alternatively I'll box it up and get the missus to drop it off at the post office with my other sale items. I can't really leave the house this week as I've got deliveries and collections coming.

p.s. The Lexurf you're referring to is now in Belfast, see Lexurf VII thread.

Cool beans, man. I'll pop over tomorrow then if that's ok with you?

If you could drop me a text message with your address (got an ancient sat nav that only accepts the first half of a post code) and contact number to get back to you I'll let you know when I'll be arriving (obviously fitting around anything you're up to).

Cheers, matey.

[Rustinho]

Thanks for sorting everything out for me today, matey. Your awesomeness is very much appreciated! :-)

[BUSHWHACKER]

You're very welcome, was nice to meet you buddy.
You got back Ok then, batteries fully charged? Nice bright headlights?
I would get that exhaust manifold leak sorted out as soon as you can.