Alternator Removal
The engine driven alternator will be located in the engine bay of the vehicle and normally bracket mounted to the engine block. Not always accessible. Sometimes other components may have to be removed before the alternator can be accessed. Disconnect battery before attempting alternator removal

Usually the alternator is  belt driven via a v belt or ribbed  belt connected to the crankshaft pulley . In a few instances the alternator may be shaft driven or gear drive. The alternator must be mounted securely to enable it to be driven efficiently. Broken or loose mounting brackets can result in loss of drive belt tension and subsequent loss of alternator performance.

 Premature alternator failure can be caused by engine oil and fluids leaking on to the unit. tTrace the source of any fluid leaks and repair prior to fitment of reconditioned alternator

Alternator Rotor
The basic vehicle alternator consists of a ROTOR with magnetic poles and an excitation winding which spins as it is driven from the engine .
The ROTOR is an electromagnet which when energised creates a magnetic field.

Alternator Stator
The housing of the Alternator consists of Stationary wires forming a "winding" of coils of wire known as a STATOR.
The stator normally consists of a soft iron laminated core around which reasonably heavy gauge copper wire is wound to form usually three windings connected in Star or delta formation. Charging voltage output of the alternator is generated in the stator.
Alternator Excitation
Power is supplied to EXCITE the rotor so the magnetic field is created. (Without excitation current there will not be a magnetic field) some alternators are SELF-EXCITED, this means after the rotor is initially excited a wire connected to the stator taps some of the power generated to keep the rotor excited and power generation in progress whilst the rotor is spinning.

The brush pack or brushes form the means of connecting the spinning rotor to the  excitation power source.
Alternator Voltage Regulation
By controlling the excitation current of the rotor the magnetic field strength is proportionally controlled. This excitation control is used to regulate the alternator output by means of the Voltage regulator.
With ECU regulated systems, the duty cycle of the excitation current can be reflected as a feedback signal to measure the amount of alternator capacity being used via the DFM signal terminal (DF Monitor).The DC voltage level produced by the alternator must be slightly higher than battery voltage to allow the battery to charge. 
Rectifier Diodes
Alternating (AC) current is produced by the alternator stator .
Unfortunately AC cannot be used to recharge the vehicle battery so has to be converted to DC . The process of converting AC power to DC power is known as rectification. The rectification is done by the Diode pack (a diode acts like a one way valve in an electrical circuit) .

Car alternators are Three Phase AC generators with rectification to DC.
The Diode pack has a secondary function when the ignition key is off to prevent the power draining from the battery via the alternator windings causing the battery to discharge.

What are the symptoms of a faulty alternator ?
The first sign of  alternator charging system  fault is often indicated to the driver by the battery charge warning light on the dash illuminating whilst the engine is running followed by gradual loss of electrical power until the engine cuts out and fails. The discharged battery can prevent the vehicle engine from being started .

Have the vehicle battery tested.

A visual check with the engine stopped should be carried out to ensure the alternator is secure and drive belt correctly tensioned. Also check for oil ,fuel or coolant leaks which may have caused the alternator to fail.

Check all connections are tight and wires are in good condition.

Check all heat shields are in place .

A quick check for a failed alternator is to measure battery voltage with the engine off using a voltmeter. Start the engine and run at around 2000rpm whilst monitoring battery voltage which should have increased slightly if the alternator is charging the battery. B+ terminal voltage at the alternator should also be checked.

Incorrect alternator output voltage ( alternator overcharging or undercharging ) can affect sensitive vehicle computer systems and related systems.

Typical battery voltage for a 12 volt system would be :

Alternator Noise possible causes:
Excess drive belt tension
Insufficient drive belt tension
Bearing failure
Stator winding fault causing phase imbalance

What causes  Alternator output to fail ?
Common causes of alternator failure are:

Broken or defective wiring to the alternator.

Wear and tear ; Worn out brushes ,sliprings, bearing failure, diode pack failure.

Excessive drive belt tension causing premature bearing failure.

Insecure mounting bolts / bracket causing insufficient drive belt tension.

Poor electrical connection causing high resistance and leading to overheating.

Electrical overload due to a defective battery or fitment of vehicle accessories, or vehicle wiring faults.

Inadequate ventilation and cooling possibly caused by fitment of vehicle body kits.

Voltage surge caused by boost starting using jump leads without surge protection. (Diode failure)

Oil, fuel or coolant leaks onto the alternator.

On modern alternators controlled by an electronic control unit an incorrect battery type may cause problems.

We have facilities to test and fault find vehicle alternators on site or remove from site for bench testing and repairs. We can also supply outright brand new or service exchange alternators for most makes of vehicle.

Can my old alternator be remanufactured ?
We offer a service exchange unit policy on most alternator , dynamo , dynastarter and starter motor units.

email enquiry wizard

Alternator Repair , Recondition , Supply, Fitting.

We can supply & fit many makes of vehicle alternator to suit your automotive charging system including replacements for Alfa romeo,AMC,Audi,AVF,BMW,Bosch,Butec,Cajavec,Carrier,Caterpillar,
CAV,Chrysler,Citroen,Cummins,Daihatsu,Delco remy,Ducellier,Efel,Elmot,Femsa,Fer,Fiat,Ford,GM,Halla,Hella,Hitachi,

Honda,Hyundai,Iskra,Isuzu,Iveco,John Deere,Kia,Komatsu,Kubota,Lada,Lucas,Magneti Marelli,A127,Magneton,

MAN,Mando,Massey Ferguson,Mazda,Mercedes Benz,MGF,Mitsuba,Mitsubishi,Monark,Motorola,Nikko,Nippondenso,

Nissan,OMC,Opel,Paris Rhone,Perkins,Peugeot,Poong sung,Prestolite,Real,Renault,Rover,214,Saab,Scania,SEV,SJCE,Skoda,Subaru,

Suzuki,Thermoking,Toyota,Unitedtechnologies,Valeo,Vauxhall,Astra,Corsa,Vectra,Zafira,Volvo,VW,Yanmar.

Please quote any reference numbers to help identify parts you may require.