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Alternator conversion help - not charging but alternator tests ok?

drooartz

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Maggie, my Morris Minor (with a A-series 1275) was converted to an alternator before I bought the car 10 years ago. Looking through the receipts I got with the car it originally had a Lucas alternator, and then when that failed a shop converted it to a GM-style alternator. The notes say it was for a Saturn SL/SW, that's all the detail I have. No obvious part number on it.

Over Memorial Day weekend I went on a long tour with my local club, from Salt Lake City, UT to Steamboat Springs, CO. About 1/4 of the way out we stopped for a little break, and Maggie would not restart (slow crank like the battery was dead). Got a jump and the car ran great for another 50 miles or so until we stopped near a parts store. Battery was too dead to test, so I bought a new one and the car fired right up. Did not have a multi-meter to test, but all seemed well and I put on at least another 500 miles that weekend.

Yesterday I took Maggie out for a spin and noticed that the engine was spinning a touch slowly on startup. Checked the battery and 11.75 volts. Started the car up and still at 11.75.

Pulled the alternator tonight (PITA given the long bolt used for the conversion, had to pull the radiator) and the local parts store tested it as OK.

So now I'm a little stumped. Could there be a loose wire somewhere making the car run OK on the alternator output, but not charge the battery? Given the number of miles I would be surprised that the new battery was only a little low and not dead again.

I did notice a wire in the mess near the alternator that was bare on one end (green/red or brown/red, hard to tell in the grime) -- might have needed to connect somewhere? The voltage regulator is long gone, alternator had one fat wire and one small one on the same single post.

Thoughts?
 
I've been reading a bit more about alternator conversions, and now I'm not even sure how the wiring on this one ever worked. I think this is a GM CS130 alternator, which should need (I think) at least one wire to the 4-pin plug on the side of the alternator. This didn't have anything to that plug.

I'm now thinking I'm going to need to clean up the wiring and start from scratch, even if I do keep this alternator on the car. Or possibly buy one of the conversion kits. I do like the idea of a simple to find Gm alternator, but maybe just getting a fresh kit makes more sense?

Either way, I really should install that volt meter I bought last year -- would have been helpful to see what's going on!
 
Sorted this out on Saturday.

Turned out that the wire that comes from the ignition light on the dash had disconnected itself from the alternator. Took a bunch of figuring and reading the wiring diagram and many articles on alternator conversions, but in the end I was victorious and cleaned up the wiring correctly. Also took the time to adjust the way the alternator mounts so I no longer have to pull the radiator to remove the alternator. One of these days I’ll get the correct alternator bracket, but for now we’re back charging properly.

Winter project will be to install a voltmeter in the dash.
 
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