3rd alternator in a month mk 7 2.2

[YellowVMan]

Not sure what to say.

1st alt stopped working, burning rubber and plastic smell, can't find what melted. the alt when removed wasn't damaged, burnt or smelt!

placed, new alt was working but started to fluctuate the voltage. arcing fault in the casing, the battery light was on only when driving, at idle no issues. faulty alt!

3rd alt, no faults with charging, voltage 14.6 no matter if the lights are on, battery light is on while driving but nothing i can see in the voltage to state a problem. Just canceled the auto electric technician due to its costing too much.

I can't see a single thing why the battery light is on only when driving, if a leave the engine at idle it will not come on, if i rev the engine the light will come on and stay on until i turn the engine off, f i start the engine its ok again.

Its not a smart charging system, its a euro 5 2.2. if there are fusing gone it won't work at all. when on earth can it be? driving 400 miles without any issues!! are there any wiring diagrams?

[longhair]

I have a Haynes manual with wiring diagram which I'll post, but I'm away till tomorrow. I'll do it straight away I get back.
.

[mallood]

i dont want to be a smartass but a wiring diagram is not gonna help you out. yes you can tell what circuits are connected to the startor circuit, but where every wire is running is just gonna be a mission of stripping stuff. You need to start taking apart your entire dash if you cant find anything that has been burned in the motorbay area.
Like you said, something has, was burning, so thats what you need to look for, and then you can check the why.

[YellowVMan]

I have a Haynes manual with wiring diagram which I'll post, but I'm away till tomorrow. I'll do it straight away I get back.
.

Thank you, that may help in some ways

[YellowVMan]

i dont want to be a smartass but a wiring diagram is not gonna help you out. yes you can tell what circuits are connected to the startor circuit, but where every wire is running is just gonna be a mission of stripping stuff. You need to start taking apart your entire dash if you cant find anything that has been burned in the motorbay area.
Like you said, something has, was burning, so thats what you need to look for, and then you can check the why.

The smell was outside but coming into the cab. There can't be that much wrong otherwise the battery light would be on all the time, idling and driving, only when it's moving. that's what's making no sense.

Someone did say about a slipping belt. so twice in a roll i told the machine to change the belt, twice in a row he didn't

[longhair]

Here you go, not sure if will be any use though.

[YellowVMan]

Here you go, not sure if will be any use though.

Thanks thats helpful to see what parts of used, as everything is working apart from the battery light on while driving, i,m looking at the battery monitoring sensor. its not a fue issues as they work or don't. any burnt cables may well causes voltage issues and that sok too.

[YellowVMan]

Here you go, not sure if will be any use though.

I think that diagram for the a smart alternator, mines a standard type.

[longhair]

Well that's what I thought but I don't know anymore. When I told you my custom had a smart alternator I was wrong. I was led to believe euro, 5 2.2s had one. Last week I wired a volt meter up to confirm it, and mine isn't. I went on a 70 mile journey and the voltage didn't drop below 14.4, so that diagram must be for a normal charging system.

[longhair]

This one is for the euro 6, 2.0 litre, and it looks quite a bit different.

[YellowVMan]

Well that's what I thought but I don't know anymore. When I told you my custom had a smart alternator I was wrong. I was led to believe euro, 5 2.2s had one. Last week I wired a volt meter up to confirm it, and mine isn't. I went on a 70 mile journey and the voltage didn't drop below 14.4, so that diagram must be for a normal charging system.

I think the they started to add the smart alts to later 2.2 with euro 5s.

There's Little to the charging system. all i can think i it is, when the first alt died it may of caused a fault code or something to come out of sync. I founded the battery neg lead of lose so tighten it expecting to feel very smart and fix the issue but nope. Yet the system works spot on.

I,m thinking it may be a damaged wires that leads to the voltage sensor somewhere.

[amlav]

Had a similar issue when I've changed my alternator on my 2006 vj with a brand new one but not Ford (charging light stayed on when driving) . Had it replaced with another new one and still the same . Altough it was charging ok (around 14V) but the light just would not go off . Took a multimeter and compared measurments of the brush holder assy. on the old original one and the new one . Found that readings where different in between the two of them . So i put the old (Ford) one back and no problem ,light went off . My problem was the pulley and I tought might as well change the alternator too but after those issues with the charge light I finished up just replacing the one way pulley on the old one .

[fortyeight]

yes burning rubber from the out side replace the alternator belt

[YellowVMan]

Had a similar issue when I've changed my alternator on my 2006 vj with a brand new one but not Ford (charging light stayed on when driving) . Had it replaced with another new one and still the same . Altough it was charging ok (around 14V) but the light just would not go off . Took a multimeter and compared measurments of the brush holder assy. on the old original one and the new one . Found that readings where different in between the two of them . So i put the old (Ford) one back and no problem ,light went off . My problem was the pulley and I tought might as well change the alternator too but after those issues with the charge light I finished up just replacing the one way pulley on the old one .

Yeah its crazy, th eonlything the garage didn't replace was the belt, had goes at telling the to replace it but they didn't way to lazy. I can't see how the light comes on only when driving yet if i leave the engine running for ages nothing happen with the battery light, but if i rev the engine a bit the light will come one with no effect on the voltage.

[YellowVMan]

yes burning rubber from the out side replace the alternator belt

Tried a few times to get the garage to replace the belt when they changed the alt but I might well have tried speaking to the brick wall.