Date:         Wed, 2 Jul 2003 23:55:30 -0500
Reply-To:     Owen <olists@THEBRANDS.ORG>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Owen <olists@THEBRANDS.ORG>
Subject:      alternator connections?
Content-Type: text/plain; charset="iso-8859-1"

I had the alternator out to repair a leaking coolant tube and when I put it back together the charge and battery light stay lit. The system is charging fine and has run without incident.

When I hooked up the alternator I attached the large positive lead. There is a smaller ground looking wire with a double hole sort of termination on it. I can't figure out where this goes. Any ideas what I overlooked?

For those that recall, the PO's mechanic had welded the alternator bracket to the coolant tube. Over time the welds developed a few pin holes. I thought I would replace this and realized that I would have to pull the engine to line up and properly drill out yet another stripped hole. Once I pulled everything out I saw why he had welded it. An attempt at drilling it out to retap was off center. I guess when I go after this I will just fill that spot with jb weld and redrill it with a center tap bit.

Thanks to coaching from the list I am comfortable with tapping and helicoils. It's a good thing. So far I have found the following items stripped:

Exhaust manifold - both sides(I will have to get this one when I drop the engine.) For now it is leaking. I may try to tighten it up before hitting the road for 5 hours.
Alternator mounting bracket (ditto)
Power steering pump - I was able to helicoil this and it is like new.

The stripped ones all had at least one of the ominous bolts with an extra nut on it. At least I no longer fear the sight of it.

Someone had requested pictures of the welding hack. I took pictures of this as well as my continuation of the hack with JB weld until I can drop the engine and repair it right. I will post a link if interested.

Owen Brand