Start and Alt!

Even though it's been a while since the last post, and the actual state of the van is far beyond what's on the blog, I will continue to update my documentation in sequential order as best I can.  While these posts may be a bit glassed over, please comment or email your questions if you want some more in depth description of what we were doing!

In this weekend project we removed both the starter and the alternator and replaced them with rebuild models.  I am very wary, especially of the alternator, as being serious potential defects after prolonged highway and rapid use.  I was able to get rebuild parts from AutoZone.com for $49 each (after core).  This is very affordable relatively and proved convenient for the core return and also promos ($15 gift card).

Besides the potential for a failed alternator or seized starter, it's very important to know that your starting and charging system is rock solid.  If you have corrosion (as found) on any of the terminals from the starter and alternator, they will work harder than they have to, can overheat, and fail.  Yes this was a preemtive repair, but provided peace of mind, especially when we would later put reasonable loads on the system (ceramic heater, subwoofer system, aux battery charging).

Please, You See!

So here's a shot of the B+ terminal on the old alternator when removing it.  Rusted to all hell, surprised it didn't snap the terminal off when loosening.  Rust like this would cause high resistance making the alternator not provide proper voltage, or low charging current.

Another shot from "undaneath"

So here we're comparing the rebuilt one to the original.  I found that the output shaft of the new one was a little longer, so I had to shim the pulley out with some washers so it could be properly clamped with the nut. 

Here's a shot of the interior of the old alternator, totally rusted out.  While alternators are brushless, I did find that there was some scraping when the shaft was turned, this may have been built up rust, or bad bearings.  Either way $50 it's piece of mind.  I've had 3 alternators go on different cars over the years, and it's quite possibly the worst experience, suddenly the car is running on a dead battery and the fuel injection system doesn't like that much :)

The position of the B+ terminal was in a slighly different place on the rebuilt alt, which meant it was going to rub on the ground metal of the engine baffles.  No good.  Cut a piece of rubber hose to shield it.  May it never rub through (or melt) XX

Nice to see that the fielding control harness fit OK.  I also took the opportunity to run an additional ground for the casing in case we had poor connection at the flange mounts.  Yeah 14 gauge wire is too small, but it's just an extra current path...

New alternator in, and belt tightened!