TECH TIP FOR MAY, 1999

FIRST, A REMINDER THAT THE SHOP WILL BE CLOSED ON SATURDAYS UNTIL THE END OF OCTOBER. IF I AM IN THE SHOP I WILL ANSWER THE PHONE AND HELP, BUT OFFICIALLY WE ARE CLOSED.

NEXT, LAST WEEK I WENT TO TEXAS TO ATTEND A TRADE SHOW/SEMINAR AND THE FOLLOWING INFORMATION IS COURTESY OF JOE DAVIS, WETHERILL ASSOC. OF ROYERSFORD, PA. THE CHANGES ARE COMING FASTER THAN EVER.

THERE HAS BEEN A CHANGE IN THE LATEST ALTERNATOR FROM DELPHI, THE CS130D. THIS IS THE ONE WHICH HAS NO EXTERNAL COOLING FAN AND THE REAR PORTION IS COVERED BY BLACK PLASTIC. WITHOUT CHANGING THE OUTSIDE, DELPHI HAS MADE A 105amp ALTERNATOR PUT OUT 20 MORE AMPS AT IDLE BUT ONLY LOST 3 AMPS FROM THE TOP END. THE ALTERNATORS SHOULD BE ELECTRICALLY INTERCHANGEABLE, BUT IF THE COMPUTERS ARE AS SMART AS WE HEAR, THEY MAY NOT LIKE HAVING TO TRY AND COMPENSATE FOR THE EXTRA LOAD AT IDLE, PARTICULARLY ON A SMALL ENGINE.

THERE IS A NEW FAMILY OF ALTERNATORS FROM DELPHI, CALLED THE "AD" SERIES. OUTSIDE OF USING A DIFFERENT STATOR  (THE PURPOSE OF WHICH IS UNCLEAR), THEIR CHIEF CLAIM TO FAME IS THAT THERE IS A CLUTCH MECHANISM INSIDE THE PULLEY, TO ABSORB THE SHOCK OF ACCELERATION/DECELERATION, ALONG WITH THE FACT THAT THE PULLEY THREADS DIRECTLY ONTO THE ROTOR SHAFT, SO THERE IS NO PULLEY NUT.

NOT TO BE LEFT OUT, FORD HAS MADE AN INTERESTING ADDITION TO THEIR "4G" SERIES OF ALTERNATORS. THE NUT HOLDING THE MAIN BATTERY CABLE TO THE ALTERNATOR, ALSO ESTABLISHES A CRITICAL CONNECTION INSIDE THE ALTERNATOR. IF THE CABLE CONNECTION WERE TO COME LOOSE, THE RESULT WOULD BE AN INTERMITTENT NO CHARGE OR A COMPLETE NO CHARGE EVEN THOUGH THE ALTERNATOR WAS STILL GOOD. I THINK IT'S MORE LIKELY THE CABLE END WILL BURN OFF. SOUND FAMILIAR?

THE "4G" ALTERNATORS ARE OUT THERE NOW ON THE 1998 VEHICLES, SO A ROUTINE MAINTENANCE ITEM NOW, IS TO MAKE SURE THAT THE MAIN BATTERY CONNECTION TO THE ALTERNATOR IS TIGHT. NOT TOO TIGHT, MIND YOU, OR YOU'LL BREAK THE POST OFF.

ON THE NEWEST VEHICLES, FORD IS USING THEIR "6G" SERIES OF ALTERNATOR (DON'T ASK WHAT HAPPENED TO THE 5G). SO FAR THE "6G" USES AT LEAST 4 DIFFERENT REGULATORS WHICH ARE PCM CONTROLLED. THE PCM CAN CONTROL IDLE, CHARGE INDICATOR LIGHT, SOFT START (DOESN'T CHARGE FULL AT START), AND LOAD RESPONSE CONTROL.

A COLLEAGUE HAS ALREADY EXPERIENCED A PROBLEM WITH ONE OF THESE. HE DOES WORK FOR A DEALERSHIP, AND THE OWNER'S WIFE WAS DRIVING A BRAND NEW 1999 WINSTAR w/3.8L WHEN THE ALTERNATOR QUIT CHARGING. MY FRIEND FOUND THAT THE REGULATOR HAD FAILED. HE HAD A REGULATOR WHERE THE PREFIX WAS ONE LETTER DIFFERENT THAN WHAT WAS ON THE ALTERNATOR AND INSTALLED IT.

THE ALTERNATOR CHARGED PROPERLY ON HIS TEST BENCH BUT ON THE VEHICLE WAS A DIFFERENT THING. WHEN FIRST INSTALLED, THE ALTERNATOR CHARGED CORRECTLY, BUT, AFTER ABOUT 30 SECONDS THE CHARGE INDICATOR LIGHT CAME ON. THE ALTERNATOR WAS STILL CHARGING BUT THE PCM WAS INDICATING A PROBLEM IN THE CHARGING SYSTEM, THERE ARE NOT ANY PARTS YET AVAILABLE FROM FORD FOR THIS ALTERNATOR ACCORDING TO HIS CUSTOMER, SO THEY TOOK A REGULATOR OFF ANOTHER TRUCK AND FIXED THE ONE THEY WERE WORKING ON. HE SAYS THE PCM HOOKS UP DIRECTLY TO THE REGULATOR ON 2 OF THE PINS, AND IT APPEARS TO BE A DATA STREAM USING A 5vt REFERENCE.

ON THE LATEST MITSUBISHI ALTERNATORS, THE LETTER "G" CAN SOMETIMES STAND FOR "GROUND" AND SOMETIMES FOR "COMPUTER". WE ALL KNOW HOW THE COMPUTER WILL RESPOND TO BEING GROUNDED.

I ATTENDED A SEMINAR BY DAN MARINUCCI OF COMMUNIQUE', ON THE HONDA CHARGING SYSTEM AND WHILE SPACE PREVENTS ME FROM COVERING ALL OF IT, HE GAVE US A QUICK, DOWN & DIRTY CHECK FOR ALL NIPPONDENSO INTERNAL FAN ALTERNATORS (LOOKS LIKE A BASEBALL WITH A PULLEY), MOST COMMONLY USED ON HONDA AND TOYOTA. THESE ALTERNATORS ALMOST ALWAYS HAVE A ROUND PLUG AT THE REGULATOR WITH EITHER 3 OR 4 TERMINALS.

AS YOU LOOK AT THE BACK OF THE ALTERNATOR, THE LEFT PIN OF THE 2 PARALLEL ONES, IS "IGNITION". PULL THE REGULATOR PLUG AND JUMP BATTERY POSITIVE TO THE "IGNITION" TERMINAL IN THE ALTERNATOR. IF THE ALTERNATOR IS GOOD IT WILL START TO CHARGE, AS LONG AS THE CASE IS GROUNDED AND THE MAIN BATTERY CONNECTION IS GOOD. IF IT FAILS TO CHARGE, PULL THE ALTERNATOR. THE ALTERNATOR WILL NOT NECESSARILY CHARGE PROPERLY UNDER THESE CIRCUMSTANCES IT WILL JUST CHARGE. IT'S A BIT LIKE THE OLD FULL FIELD TEST.  SO, WITH THE REGULATOR WIRING DISCONNECTED, JUMP POWER TO THE "IGNITION" TERMINAL IN THE ALTERNATOR, SIMPLE HUH!