Denso Alternator

I'd been having some more issues with my Lucas alternator, so I took it apart and ordered a service kit, which included bushes, bearings, rectifier and regulator.  I started to overhaul the alternator, but during the process I decided that I was not really happy with the situation.  I wasn't convinced that I would not have further problems in the future, so I finally took the plunge and ordered a genuine Denso alternator.

The new alternator is rated at 40 amps, so should be more than sufficient for the modest electrical loads that my Avon can generate.  It weights about 2kg versus the 3kg of the Lucas, so there is a nice weight saving too.

When I removed the Lucas alternator I discovered that the lower mounting bracket had failed.  The front lug had snapped off and it was just the rear lug that was holding the alternator on.  It was lucky that I discovered this in the garage and not at the side of the road!

I took the old lower bracket to the local fabricator/welders.  They removed the old lugs and added strong new fixings for the Denso.

For the alternator tensioner I re-used the old upper bracket and connected it to the alternator with two rod ends and some 8mm threaded rod.

The main output connection is a threaded copper post.  I had a proper battery cable made up that had the correct size ring connector for the alternator on one end and the correct size at the other to connect to the starter motor connection (where the car's main loom terminates the +12v).  This arrange should be much better than the Lucas spade connections, which are prone to arcing.  The cable is more heavy duty than the original Tiger alternator output wire, so this can only help.

Alternator Problems

I've had an issue recently with the alternator.  It was a new Brise 16004 alternator supplied by Tiger and its only done 1700 miles.  I noticed something was wrong when I could see the headlights flickering.  Only noticeable on side lights.  I checked the battery voltage with the engine running and it was erratic, sometimes above 15 volts.  If left this was going to damage my battery.

I checked all the wiring, the belt tension and the alternator plug, but everything seemed normal.  I decided to take the alternator to a local alternator and starter motor specialist.  I wanted it fixed quickly and I wasn't sure how long it would take if I sent if back to Tiger or how much the postage would cost.  I did contact Brise by email regarding the warranty, but I've still not heard back.

In the end it turned out to be a simple fix.  All the connections on the regulator had vibrated loose (or not been correctly tightened by Brise during manufacture).  The regulator had also failed, possibly as a result of working loose.  The alternator repair shop fitted a new regulator during the same day.  I've refitted the alternator and now I've got a nice steady 14.2 volts.