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Glyn Harper

Alternator replacement

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So after 2 years of not getting my Esprit out of the garage, all the jobs I'd put off are coming back to haunt me!

Next job is the alternator.

Annoyingly, the internals of the alternator itself are good. I had it serviced about 10 years ago by a local specialist (now gone) and he fitted new brushes and all sorts of internal bits that made it like new. It's probably only done 2,000 since.

Problem is, where the main top stud goes through the alternator housing, the actual hole in the housing has worn into a slot.

This has made the alternator loose, allowing it to rattle, which has in turn made the problem worse. It really flops around now.

I tightened it up when I noticed this wear a couple of weeks back but it's loose again already after about 60 miles of use. The hole is now more a slot than a hole, so I don't think I've got much chance of stopping the problem.

So, it looks like I either need to repair or replace. But I'm not sure the slot could be welded up or not without damaging the Internals.

SJ Sportcars do new ones for about £250, but does anyone know a cross reference for the alternator so I can maybe get one a bit cheaper? Or anyone got a spare they'd be willing to part with?

Had the car 19 years from being 27 years old.. but now I'm 46 years old I'm losing my enthusiasm to spend 4 hours repairing for every 1 hour I spend driving! I need to pull my finger out though as I gather our cars are going up in value. And it looks ace so it needs to be on the road.

My car is an '88 turbo, by the way.. UK spec, Renault box.

cheers all  

 

Edited by Glyn Harper

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Can't you drill out the worn out hole to a bigger size and fit a sleeve around the bolt? That should take up the play it now has.

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I have made many mistakes in my life. Buying a multiple Lotus is not one of them.

 

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That's the plan, but I don't know if it's too far gone. May engineer pal (who also builds rally cars) is going to have a look for me. Have a look at the photos. :(

 

Photo 23-07-2017, 5 46 59 pm.jpg

Photo 23-07-2017, 5 47 11 pm.jpg

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That does look pretty bad, but I'd give it a try to fit a sleeve and fill with metalepoxy or such.


I have made many mistakes in my life. Buying a multiple Lotus is not one of them.

 

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The Bosch AL49X is cited as a replacement (with improved output)  in quite a few threads. It's not a drop in replacement and needs some minor work for it to fit.

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If you search the forum for 'AL49X' there's quite a few threads about it, from memory it's repositioning the rear so that the electrical connectors are in the correct place and fitting the OE pulley to it.

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Thanks, yeah I've just started searching and found a few threads on the US site. 're clocking' they call it.

I'll see if I can find one as a backup to my one being fixed.. which would obviously be the cheapest option. :)

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I realize this thread is 12 years old, However, I had my alternator replaced last month. I have put just over 150 miles on my 1989 Esprit Turbo and today the "battery not charging" tell tale lamp has come on and my Esprit is running like SH*%T! also the headlamps turned off on there own as I was driving down the road. Car really seem to be struggling to stay running. Too late and dark out to work on Her anymore tonight.

I had my Local Lotus Guru put a German made alternator in which He recommended.  I am guessing I should get my multimeter out and see if the alternator is making any electricity for starters.. If anyone has any suggestions I would greatly appreciate it.

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Quick visual look to make sure drive belt is still there or maybe it is loose,   check actual battery terminals for tightness, check alternator wires visually and check the connections are tight.  Also check with a multi meter,  :)

The lights will of switched off throught lack of power and the engine will be running badly as the power to run the engine i.e sparks, injectors, fuel pump will be struggling for power due to low  voltage feed  imo. 


A

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10 hours ago, Herbert Harvey said:

I realize this thread is 12 years old, However, I had my alternator replaced last month. I have put just over 150 miles on my 1989 Esprit Turbo and today the "battery not charging" tell tale lamp has come on and my Esprit is running like SH*%T! also the headlamps turned off on there own as I was driving down the road. Car really seem to be struggling to stay running. Too late and dark out to work on Her anymore tonight.

I had my Local Lotus Guru put a German made alternator in which He recommended.  I am guessing I should get my multimeter out and see if the alternator is making any electricity for starters.. If anyone has any suggestions I would greatly appreciate it.

It's only a recent thread actually. :)

As Dan said, make the checks above.

I had a similar issue years ago on my Ford Escort (but same principle) as this, and it turned out I'd forgotten the thinner wire that connects onto the alternator. This is what essentially tells the alternator what load is required and how much power to produce. If this wire isn't connected (or broken further up) then you'll get exactly this problem.

Some of the wires in the engine bay go brittle, so although it may look connected you need to make sure it's connected all the way. Brown and yellow it is and usually has a spade connector on the end.

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I second taht of Glyn, as I had that thin wire have a bad spade connector which led to same problem. So pressed it a bit and voila, all good.

Kind regards,

Jacques


Nobody does it better - than Lotus ;)

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Thanks Glyn and Jacques,

I looked inside the engine bay this morning, found my broken alternator belt just sort of hanging out in the engine bay.. Luckily it didn't get the chance to get wrapped up into any of my other belts.. Ordered New belt, pick it up tomorrow and will put it in right away.. Plan on checking the alternator output after i Install it.  just to make sure its doing its job.. 

Thanks again, If I had purchased my Esprit before the internet and the Lotusforums I would have most likely been up the creek with out a paddle!

 

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21 minutes ago, Herbert Harvey said:

Thanks again, If I had purchased my Esprit before the internet and the Lotusforums I would have most likely been up the creek with out a paddle!

 

And so say most of us.:)

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Good to hear it was an easy fix and no damage done. :)

Just to add, the thin wire is not to regulate power, but to provide tension to the coils to excite them and allow the alternator to produce current. If you're lucky, it will charge even without start-up voltage, but that's not reliable.


I have made many mistakes in my life. Buying a multiple Lotus is not one of them.

 

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Pretty sure the Motorola one I replaced on mine is a VW derivative. But with the original pulley wheel I'm sure it was less than £100. As they speced it up while I was there. This was a couple of years back. I also had the same whole issue which was solved with a sleeved insert.


It's Oogies turn to boogie

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