Subject
Alternator Harness Check
Vehicles
Frontera 23 DTR up to V.I.N. NV512500
Condition
It has been found that on some of the above mentioned vehicles there is a possibility of the alternator harness being damaged through contact with the rear end of the alternator body and plastic deflector. To eliminate any risk of damage, which could potentially lead to a short circuit fault, it is recommended that the next time a vehicle built within the specified chassis range is booked into your workshop, it should be checked and, if necessary, reworked according to the following information.
Visual check
1. Establish which routing configuration is present on the vehicle, referring to figure U3928 and U3929.
Figure U3929 represents the currently built standard with improved routing and does not require checking.
2. Check the condition of individual cables of the alternator harnesses in the area A shown in figure U3928. If damage to any of the cables is observed or suspected, the following rework operation should be carried out.
(Inspection can be carried out using a torch and mirror).
Note:
| It is permissible to repair the blue/white (ignition warning light) and green (tachometer lead) cables provided that the repairs are carried out to approved standards. If the main cable (red) shows any signs of damage, it is recommended that both the harness and plastic deflector be replaced. | .P. U3928.tif | 9 | 7,5 | tiff;; |
A Passage Alternator Harness through Deflector
B Red Cable
C Blue/White Cable
D Green Cable
E Deflector
F Plastic Tie
| G Alternator Harness | |||
|---|---|---|---|
| .P. U3929.tif | 9 | 7,5 | tiff;; |
Rework operation
Harness and cover replacement can be achieved without having to remove the alternator from the vehicle.
The procedure is as follows:
Remove the battery.
Remove the fan belt and the adjuster bolt from the alternator.
Remove plastic tie from around the plastic deflector (reusable) and the plastic ties securing the harness.
Disconnect the vacuum hose from the vacuum pump.
Disconnect alternator harness from the starter (red cable), the engine harness (twin connector) and the alternator.
Swing the alternator towards the left hand inner wing panel and remove the alternator harness and deflector assembly from the alternator.
Install the new deflector. Ensure that the replacement alternator harness and plastic deflector are pre-assembled before fitting to the alternator.
Refit the fan belt and the adjuster bolt to the alternator, check the fan belt tension by applying tool KM-128-A.
Reconnect the alternator harness to the starter and the engine harness and the alternator.
Reconnect the vacuum pipe to the vacuum pump outlet.
Refit the plastic tie around the deflector and the plastic ties securing the harness to the vacuum pipes.
Refit the battery.
Start the vehicle to confirm satisfactory operation of the fan belt and alternator.
Parts Part No. Catalogue No.
Alternator Harness 90 458 387 12 95 701
Deflector 90 448 227 12 05 809
Time allowance X390601 Alternator Harness Check/Replace 1.2 hrs
TC:99