Disco 2 Alternator Removal - Battery Red Warning Light

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Intestinalworm

Intestinalworm

Well-Known Member
Posts
712
Location
Australia
2003 Discovery 2 Td5 (250,000 kilometres)

Driving along on the highway - all good, suddenly noticed the red "battery" warning light come on and stay on. Around 15km from home, so turned around and headed home without issue, but with the warning light on all the way. When I got home, just to be sure, I turned off the engine, waited, and then turned the engine on again - red "battery warning light on again!

Checked battery terminals - nice and secure. Got multimeter and checked battery (battery only six months old) - 12.1V. Turned ignition on and measured: 11.8V, then 2 seconds later it jumped to 12.9V with a change in sound! Thinking alternator now, but maybe pulley bearing is an issue here (sound change)? I put a new tensioner (bearing gone on the old/original one) and serpentine belt on several months ago, and shortly thereafter there was a bit of a rattling sound which I never got around to diagnosing.

The alternator/vacuum pump pulley/bearing is all original - never been touched.

So, I guess I first need to get the alternator out and have a look!

Is there a good guide anywhere on how best to get the alternator out? RAVE? Any special tools required?

Secondly, I notice that a new Denso alternator here in Australia costs AUD590 (delivered)!

Can you change the brushes on the alternator if that's the issue? Not sure regards the rectifier pack? Maybe just pulley bearing?

Short of money at the moment so wondering if I have options that could save me a bit?
 
It does sound like the alternator is dead. Not just the brushes, but also the regulator/rectifier and bearings to consider.
It could be a brush issue but i bet it's the reg/rec. Should be replaceable too. If the bearings aren't noisy then it's worth a shot.
Make sure you fully charge the battery as soon as you can, below 12.4v and damage will soon start (sulphation).
 
Okay, will look at pulling out the alternator vacuum pump tomorrow and having a look.

Checked out RAVE - with vacuum line and the oil in and oil out lines, do they just pull out by hand? No (special) tool or technique required?

Here in Australia (local pick-up in Melbourne) I did find this:

http://lankaauto.com.au/product/new-alternator-parts-fit-landrover-discovery-2-td5-2-5l-diesel/
(AUD 150)

or a new alternator/vacuum pump here (same auto electrician shop):

http://lankaauto.com.au/product/new...overy-2-td5-2-5l-diesel-10p-16p-1999-to-2005/
(AUD 299)

If I bought a Denso OE alternator/vacuum pump then it would cost AUD 590 delivered price from an online Australian supplier.


What is the bearing inside the pulley on the vacuum pump? Does anyone know?

Noticed RAVE said to replace the o-ring in the vacuum pump oil line??? Does anyone know what size it is? Viton?
 
Last edited:
kermit_rr said:
It does sound like the alternator is dead. Not just the brushes, but also the regulator/rectifier and bearings to consider.
It could be a brush issue but i bet it's the reg/rec. Should be replaceable too. If the bearings aren't noisy then it's worth a shot.
Make sure you fully charge the battery as soon as you can, below 12.4v and damage will soon start (sulphation).
Click to expand...


I've seen brush/box on eBay and a local supplier sells the brush box and the rectifier pack for AUD 150 as per the link. Why do you think it wouldn't be the brushes and more likely to be the rectifier pack?

I did have oil leaking from the front camshaft seal for a while (has been fixed for some time though) - read that oil can cause alternator issues (not quite sure with what part/s though?)
 
Do you have anyone there who will recondition your alternator ?? We have a company locally who have been doing this with alternators and starter motors for years. I would expect to pay about £100 or less for a recon.
 
meego said:
Do you have anyone there who will recondition your alternator ?? We have a company locally who have been doing this with alternators and starter motors for years. I would expect to pay about £100 or less for a recon.
Click to expand...

Unfortunately Easter shut-down is upon us and I need to get the Disco up and running asap - worried reco could take a while. I will look-around though and look at that option. With the AUD150 I believe that has all the parts to do a reco yourself?
 
I've heard that parts (brush box, rectifier, etc.) for the Denso alternator in the Disco 2 Td5 (and Defender?) are available from Toyota dealers as LandCruisers use the same model alternator. Is that right? Does anyone know the part numbers?
 
meego said:
Do you have anyone there who will recondition your alternator ?? We have a company locally who have been doing this with alternators and starter motors for years. I would expect to pay about £100 or less for a recon.
Click to expand...
Couldn't agree more, and once done you have a place to go back to if it goes wrong. My guy never gets it wrong, it wouldn't be worth his while, and far cheaper than a new one. Plus he only does what needs doing after testing it.

I beleive there is a seal between the alternator and the vacuum pump which, if it leaks, does the alternator no favours.
Ministry of Cr@p Design, yet again!
 
Stanleysteamer said:
Couldn't agree more, and once done you have a place to go back to if it goes wrong. My guy never gets it wrong, it wouldn't be worth his while, and far cheaper than a new one. Plus he only does what needs doing after testing it.

I beleive there is a seal between the alternator and the vacuum pump which, if it leaks, does the alternator no favours.
Ministry of Cr@p Design, yet again!
Click to expand...

Been looking around, RAVE mentions this o-ring, and I believe the details are here:

“Lip Seal (alternator to vacuum pump)
Measures 17 mm x 30(37) mm x 8 mm
Nippon Denso 081103-0080
Common to a few Toyota alternators, can use Toyota p/n 29341-64130”

Trying to work out if I can buy a rectifier/regulator and brush box from Toyota as well?

Does anyone know a good (recommended) Denso alternator reconditioner in Melbourne, Victoria, Australia?
 
Intestinalworm said:
Unfortunately Easter shut-down is upon us and I need to get the Disco up and running asap - worried reco could take a while. I will look-around though and look at that option. With the AUD150 I believe that has all the parts to do a reco yourself?
Click to expand...
I'd do that then, if you are happy about doing it. Just make sure the seal between it and the vacuum pump is new.
Why do you ask about the bearing, are you suspicious it is worn beyond where it ought to be?
 
Stanleysteamer said:
I'd do that then, if you are happy about doing it. Just make sure the seal between it and the vacuum pump is new.
Why do you ask about the bearing, are you suspicious it is worn beyond where it ought to be?
Click to expand...

Yes, glad I read about that seal (mentioned in RAVE that it has to be replaced)!

I recently replaced the bearing in my A/C pulley and also put a new tensioner in (bearing very scratchy), so I'm assuming the bearing inside the pulley should ideally be replaced?

I guess there would also be a bearing at the back of the alternator, but don't know if that is easily accessible/replaceable?

Guess I'll know a bit more when I pull the unit out?
 
Intestinalworm said:
Yes, glad I read about that seal (mentioned in RAVE that it has to be replaced)!

I recently replaced the bearing in my A/C pulley and also put a new tensioner in (bearing very scratchy), so I'm assuming the bearing inside the pulley should ideally be replaced?

I guess there would also be a bearing at the back of the alternator, but don't know if that is easily accessible/replaceable?

Guess I'll know a bit more when I pull the unit out?
Click to expand...
Best of luck with it all. Although I have "done" quite a few alternators, I've never done the one on my D2.
 
Intestinalworm said:
Unfortunately Easter shut-down is upon us and I need to get the Disco up and running asap - worried reco could take a while. I will look-around though and look at that option. With the AUD150 I believe that has all the parts to do a reco yourself?
Click to expand...
I can only comment on our guy and he usually has one on the shelf surprisingly. If not, drop off mine one day, pick up the next.
 
westone said:
If you put your DVM on AC volts setting, run DIsco at about 2000rpm you should not get a reading.
If you do means diode pack is failed or failing in alternator.
Hope you get it fixed.
Click to expand...

That's something that's great to know!!! Thanks! I did wonder if there was a way (DMM tests) to determine whether the rectifier and/or regulator were faulty; I guess if the brushes are worn away then that is obvious! Brushes have done 260,000km so I'm guessing they might have just given up the ghost!?

Will be pulling out the alternator itself on Monday when I have time (have already pulled the battery/ECU/battery box/intercooler pipe/serpentine belt and tensioner out) - bit busy over Easter with a few other things. The only big problem was finding the 12-sided socket (14mm) - spent hours looking for it!!! I had forgot it was 12-sided!

Hoping to clean the alternator and replace the brush box holder only for no! May do bearings another time, along with rectifier and regulator (if not required now).
 
westone said:
If you put your DVM on AC volts setting, run DIsco at about 2000rpm you should not get a reading.
If you do means diode pack is failed or failing in alternator.
Hope you get it fixed.
Click to expand...

Rectifier converts AC to DC, so if it's (rectifier) not working thenAC voltage will be measured on the battery leads? The battery posts itself show c.12.6V? Is this what you mean?
 
Yes put your leads on battery posts,12.6v is high, you sure you have your meter on on AC?

If thats 12.6volts AC your diode pack has failed..... You should get 0 or hardly anything as your right engine produces AC with alternator diode pack converts to DC so car can use it.

Check on your DC setting and see what you get. If your getting that amount of AC will be hardly anything.....AC is nasty causes lots of spikes and stuff...horrible!
 
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