Alternator
08-08-2007, 07:36 AM
#21
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10. Begin adding your new cables along side the existing ones. I usually begin with the alternator positive cable. Locate the output stud on your alternator and remove the nut. Slip the new cable onto the lug and replace the nut. There is no need to disturb the existing cabling. Route the new cable to the battery and position it to connect to the positive battery post (or connect it to the positive terminal on the OEM wiring) but do not connect the battery yet.
11. Secure the new cable in place by using cable ties every 6 to 8 inches. Secure the cable to cool non-moving parts!
12. Locate where the negative battery cable attaches to the vehicle chassis. Remove this bolt and the OEM battery cable, and clean the mounting area of the chassis using scotch brite and/or a wire brush. Make sure there is no dirt, rust, paint, undercoating, etc in this location. You want bright shiny metal. Connect both your new ground and the OEM ground back to the chassis. NOTE: Some people like to create a new ground location by drilling into the chassis and using a bolt with star lock washers for the new ground cable. Route this new cable back to the battery and position it to be attached, or connect it to the negative terminal. Do not reconnect the battery yet.
13. Secure the negative cable using cable ties every 6-8 inches. Again, don't tie it to anything that moves or that gets hot!
14. Disconnect the engine ground strap at both ends. Using the wire brush or scotch brite, clean both the engine block and the chassis as you did for the first ground strap.
15. Line up the lugs on both the OEM ground strap and your new ground cable, and use cable ties to secure them to each other. This is much easier to accomplish in your lap or on the floor than it is while lying under your car or hanging upside down in the engine compartment. Reinstall both cables at the same time using the factory bolts.
16. Double check to make sure all bolts are tight. Be careful not to over-tighten them as you don't want to strip anything! Also, on some factory alternators it is WAY too easy to twist off the positive output lug. If you break it off, well hell, you really wanted a high-output alternator anyway, right? It is also a good idea at this point to measure resistance of the new cables. Take an ohm reading between the battery end of the new ground cable and the engine block. It should read less than one ohm. Also check between the alternator bolt and the disconnected positive battery terminal, which should also be less than one ohm. If you read too high resistance, double check all connections and make sure you do not have something c**ked sideways or hanging loose.
NOTE: Realize that the "absolute ground" of the electrical system is not the battery negative terminal or the vehicle chassis, but is the case of the alternator itself. This is why perhaps the most important cable among the Big 3 is the engine ground strap, as this is what connects the alternator ground to the vehicle's chassis. Be certain the resistance between the alternator case (the engine block assuming the alternator is properly bolted to the engine) and the battery negative is minimized. (Thanks to the12volt for pointing this out!)
17. When you are sure you are done and anything in your system that you may have disconnected are re-connected, clean your battery posts and reconnect the positive battery terminal first, then the negative one.
18. Start your vehicle. Hopefully the engine starts.
Examine the engine compartment and make sure none of your cables are getting hot or are vibrating or shaking around. If they are vibrating too much you may need to relocate them or use more cable ties. If you see smoke, immediately shut off the car and disconnect the battery. Seek help.
19. Assuming all looks good, take a voltage reading at your amplifier and ensure you read 13.8 (or higher) volts. This indicates a properly operating charging system.
20. Now'd be a good time to turn it on and make sure it sounds good! Then of course log onto the12volt.com and post that you have upgraded your Big 3!
Courtesy of the12volt.com
11. Secure the new cable in place by using cable ties every 6 to 8 inches. Secure the cable to cool non-moving parts!
12. Locate where the negative battery cable attaches to the vehicle chassis. Remove this bolt and the OEM battery cable, and clean the mounting area of the chassis using scotch brite and/or a wire brush. Make sure there is no dirt, rust, paint, undercoating, etc in this location. You want bright shiny metal. Connect both your new ground and the OEM ground back to the chassis. NOTE: Some people like to create a new ground location by drilling into the chassis and using a bolt with star lock washers for the new ground cable. Route this new cable back to the battery and position it to be attached, or connect it to the negative terminal. Do not reconnect the battery yet.
13. Secure the negative cable using cable ties every 6-8 inches. Again, don't tie it to anything that moves or that gets hot!
14. Disconnect the engine ground strap at both ends. Using the wire brush or scotch brite, clean both the engine block and the chassis as you did for the first ground strap.
15. Line up the lugs on both the OEM ground strap and your new ground cable, and use cable ties to secure them to each other. This is much easier to accomplish in your lap or on the floor than it is while lying under your car or hanging upside down in the engine compartment. Reinstall both cables at the same time using the factory bolts.
16. Double check to make sure all bolts are tight. Be careful not to over-tighten them as you don't want to strip anything! Also, on some factory alternators it is WAY too easy to twist off the positive output lug. If you break it off, well hell, you really wanted a high-output alternator anyway, right? It is also a good idea at this point to measure resistance of the new cables. Take an ohm reading between the battery end of the new ground cable and the engine block. It should read less than one ohm. Also check between the alternator bolt and the disconnected positive battery terminal, which should also be less than one ohm. If you read too high resistance, double check all connections and make sure you do not have something c**ked sideways or hanging loose.
NOTE: Realize that the "absolute ground" of the electrical system is not the battery negative terminal or the vehicle chassis, but is the case of the alternator itself. This is why perhaps the most important cable among the Big 3 is the engine ground strap, as this is what connects the alternator ground to the vehicle's chassis. Be certain the resistance between the alternator case (the engine block assuming the alternator is properly bolted to the engine) and the battery negative is minimized. (Thanks to the12volt for pointing this out!)
17. When you are sure you are done and anything in your system that you may have disconnected are re-connected, clean your battery posts and reconnect the positive battery terminal first, then the negative one.
18. Start your vehicle. Hopefully the engine starts.
Examine the engine compartment and make sure none of your cables are getting hot or are vibrating or shaking around. If they are vibrating too much you may need to relocate them or use more cable ties. If you see smoke, immediately shut off the car and disconnect the battery. Seek help. 19. Assuming all looks good, take a voltage reading at your amplifier and ensure you read 13.8 (or higher) volts. This indicates a properly operating charging system.
20. Now'd be a good time to turn it on and make sure it sounds good! Then of course log onto the12volt.com and post that you have upgraded your Big 3!
Courtesy of the12volt.com
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