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Alternator 16

OPERATION - FAULT FINDING

These vehicles are fitted with alternators with in-ternal ventilation, an integral regulator and a warning light on the instrument panel which ope-rates as follows :

- when the ignition is turned on, the warning light illuminates,

- when the engine starts, the warning light ex-tinguishes,

- if the warning light illuminates again when the engine is running, there is a "charging"

fault.

LOOKING FOR FAULTS

The warning light does not illuminate when the ignition is turned on.

Check:

- the electrical connections are correct,

- the bulb is not blown (to do this, earth the cir-cuit; the bulb should illuminate).

The warning light illuminates when the engine is running

There is a charging fault which could be due to:

- the alternator drive belt being broken or the charging cable being cut,

- internal damage to the alternator (rotor, sta-tor, diodes or brushes),

- regulator fault, - an excess voltage.

The customer complains of a charging fault and the warning light operates correctly.

If the regulated voltage is less than 13.5 V, check the alternator. The fault could be caused by:

- a destroyed diode, - a cut phase,

- track contamination or wear.

Checking the voltage

Connect a voltmeter across the battery terminals and read the battery voltage.

Start the engine and increase the engine speed until the voltmeter needle stabilises at the regulated voltage.

This voltage should be between 13.5 V and 14.8 V.

Connect as many consumers as possible, the regulated voltage should remains between 13.5 V and 14.8 V.

IMPORTANT: if arc welding is carried out on the vehicle, the battery and the regulator must be disconnected.

Alternator 16

- the alternator drive belt, together with bolt (3) and shaft (4), removing through opening (5),

REMOVAL

With the vehicle on a 2 post lift, disconnect:

- the battery,

- the alternator electrical connections.

Remove:

- the power assisted steering belt by slackening the three bolts (1) and the nuts (2) for the ten-sioner,

E 7 J and K 7 M engines

SPECIAL TOOLING REQUIRED Mot. 1273 Tool for testing belt tension T. Av. 476 Ball joint extractor

Upper shock absorber mounting bolt 3

Track rod end nut 3.5

Wheel bolts 9

TIGHTENING TORQUES (in daN.m)

98747R1

98745R2

- the front right hand wheel,

- the track rod end (6) using tool T. Av. 476,

98712R

STARTING - CHARGING

Alternator 16

- the two upper shock absorber mounting bolts (7).

98709R1

Press downwards on the front axle assembly to make removing the alternator easier through the front right hand wheel arch.

REMOVAL

Refitting is the reverse of removal.

Special notes:

- do not refit the old drive belt, renew it, - refer to section 07 for tension values.

E 7 J and K 7 M engines

Alternator 16

REMOVAL

(there are no special notes for engines fitted with power assisted steering)

To release the alternator shaft the following must be removed:

- the mounting bolts (1) for the coils, - the two bolts (2) from the coil mounting.

Slacken bolt (3) then slide the mounting down.

98899R1

REFITTING

Refitting is the reverse of removal.

F 3 R engine

STARTING - CHARGING

Alternator 16

REMOVAL Disconnect:

- the battery,

- the alternator electrical connections.

Remove the mounting bolt for the diesel fuel pipe retaining bracket and move it to one side.

98837R

Slacken bolt (A) then bolt (B), to just past the shoulder, while holding the automatic tensioner plate with a 9 mm wrench (Eg. : FACOM J 151 rat-chet), then slacken the belt by moving the ratchet in the direction of the arrow.

F 8 Q engine with AC

Remove:

- the lower timing cover, - the belt,

- the alternator mounting bolts, - the alternator.

REFITTING (Special note)

Refitting is the reverse of removal.

The belt is tensioned by moving the automatic tensioner plate against the stop at bolt (B), wi-thout forcing it, using a 9 mm wrench (Eg. : FACOM J 151 ratchet ).

98837-1R1

NOTE : do not refit a belt once it has been remo-ved.

Alternator 16

OPTIMA 5800 diagnostic station

CHECKING THE CHARGING CIRCUIT USING THE DIAGNOSTIC STATION

The OPTIMA 5800 diagnostic station is used to test the alternator by measuring the voltage and current flow, with and without electrical consumers.

NOTE : the ampermetric clamp on the station is of the inductive type (measuring range : 0 to 1000 A). It may be positioned without disconnecting the battery, which allows computers to retain their memory and set-tings.

Depending on the engine, the ampermetric clamp may be positioned in different locations (the diagnostic station will detect incorrect positioning) :

- F3R, F8Q engines : directly at the alternator output, the arrow on the clamp pointing towards the alterna-tor.

- E7J, K7M engines : on the cable connecting the positive battery terminal to the alternator (this cable crosses the battery compartment partition).

Measurements are made in three stages:

- measurement of battery voltage, ignition off,

- measurement with no consumers of the regulated voltage and current flow,

- measurement with the maximum number of consumers of the regulated voltage and current flow.

At the end of the test, the values noted will form the basis of a diagnostic report message:

- Battery voltage no load < 12.3 V = battery discharged.

Without consumers:

- Regulated voltage > 14.8 V = > regulator faulty,

- (Regulated voltage no load < 13.2 V) or (charging current < 2 A = > charging fault).

With consumers:

- Regulated voltage > 14.8 V = > regulator faulty,

- Regulated voltage < 12.7 V = > check the alternator flow with reference to its specifications:

Engine E7J K7M F3R F8Q

Without air conditioning 75 (45) 75 (50) 75 (50) 75 (50)

With air conditioning / 110 (80) 110 (80) 110 (80)

Notes for the table: - Current values in Amps.

- The value in brackets corresponds to the minimum flow which should be supplied by the alternator when all consumers are connected.

FAULT FINDING

SPECIAL TOOLING REQUIRED

STARTING - CHARGING

Alternator 16

If the measured flow is too low, check:

- if the alternator is worn (brushes....), - the battery connections,

- the engine earth strap,

- the conformity of the alternator, - the belt tension.

If the flow measured is correct and the regulated voltage is too low, the alternator is not at fault.

The fault is caused by :

- the vehicle having too many consumers or, - the battery being discharged.

FAULT FINDING (cont)