Alternator & Regulator Saturn SL I

DESCRIPTION

CS series alternators include a stator, rectifier bridge, and rotor with slip rings and brushes. A built-in regulator incorporates fault detection circuitry.

Most CS series alternators operate with 2 wire connections and a ground path through the mounting bracket. The first wire connection is the BAT (output) terminal. This terminal must be connected to the battery during operation. The second wire connection is through the charge indicator light or an external resistor to terminal "L" of the regulator. This connection provides initial excitation at start-up.

One other regulator terminal, "I", is provided for optional use. Terminal "I" provides an alternative method for turning on the alternator without going through the indicator light or external resistor.

ADJUSTMENTS

No adjustment or maintenance is required on alternator assembly. Regulator voltage is preset and no adjustment is possible.

TROUBLE SHOOTING

Note. See the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

ON-VEHICLE TESTING

CHARGE WARNING LIGHT DOES NOT LIGHT

1. Visually check alternator belt and wiring. Turn ignition switch to ON position (engine not running). Charge light should come on. If light does not illuminate, check IGN 1 and IGN 4 fuses.
2. Check circuit No. 2B (fusible link wire) for an open from battery to starter solenoid contact. Check circuit No. 2C (fusible link wire) for an open from starter solenoid contact to alternator battery terminal.
3. Check circuit No. 3A (Pink wire) for an open from ignition switch to instrument panel junction block located under center of instrument panel, directly in front of console.
4. Check circuit No. 39C (Pink/Black wire) for an open from instrument panel junction block to instrument cluster charge light bulb. Check circuit No. 25 (Brown wire) for an open from instrument cluster charge light bulb to underhood junction block located on inner fender panel under hood.
5. Check circuit No. 25A (Brown wire) for an open from underhood junction block to alternator terminal "L". Check instrument cluster, alternator and ignition switch connections for poor contact.

CHARGE WARNING LIGHT STAYS ON AT ALL TIMES

1. Visually check alternator belt and wiring. Turn ignition switch to START position. Charge light should cycle on and off after engine starts.
2. Check circuit No. 25 (Brown wire) for a short to ground from instrument cluster charge light bulb to underhood junction block located on inner fender panel under hood.
3. Check circuit No. 25A (Brown wire) for a short to ground from underhood junction block to alternator terminal "L". Check instrument cluster, alternator and ignition switch connections for poor contact.
4. Check for constant engine running at low RPM. Check for excessive electrical drain. Using a carbon pile load tester, perform alternator load test. See «BATTERY/ALTERNATOR LOAD TEST (ARBST TEST)»(/saturn/sl/i-1990-1995/remont/charging-system/#alternator-regulator__batteryalternator-load-test-arbst-test) under ON-VEHICLE TESTING. Check for loose or broken drive belt.

BATTERY UNDERCHARGED

Note. Ensure battery is fully charged and in good condition before performing the following steps. If battery is not at (or near) a fully charged condition, or if its condition is questionable, substitute a known good battery before proceeding.

1. Check circuit No. 15A (battery ground). Check circuit No. 2B and 2C (fusible link wire) from battery positive to starter solenoid contacts and from starter solenoid contacts to alternator.
2. Check for parasitic drains by performing parasitic load testing. See «PARASITIC LOAD TEST»(/saturn/sl/i-1990-1995/remont/charging-system/#alternator-regulator__parasitic-load-test) under ON-VEHICLE TESTING. Check for constant engine running at low RPM. Check for excessive electrical drain.
3. Using a carbon pile load tester, perform a alternator load test. See «BATTERY/ALTERNATOR LOAD TEST (ARBST TEST)»(/saturn/sl/i-1990-1995/remont/charging-system/#alternator-regulator__batteryalternator-load-test-arbst-test) under ON-VEHICLE TESTING. Check for loose or broken drive belt.

BATTERY OVERCHARGED

Check alternator electrical connectors. If connectors are okay, replace alternator.

LIGHTS DIM IDLING

1. Check for constant engine running at low RPM. Check for excessive electrical drain.
2. Using a carbon pile load tester, perform a alternator load test. See «BATTERY/ALTERNATOR LOAD TEST (ARBST TEST)»(/saturn/sl/i-1990-1995/remont/charging-system/#alternator-regulator__batteryalternator-load-test-arbst-test) under ON-VEHICLE TESTING. Check for loose or broken drive belt.

LIGHTS DIM OVER 1000 RPM

Check for loose or broken drive belt. Check for loose or broken alternator mounting bolts.

NOISY ALTERNATOR

Check for loose or broken drive belt. Check for loose or broken alternator mounting bolts. If belt and mounting bolts are okay, replace alternator.

RADIO NOISE/HUM OR WHISTLE

Check alternator electrical connectors. If connectors are okay, replace alternator.

ALTERNATOR OUTPUT EXCEEDS 16 VOLTS

Check alternator electrical connectors. If connectors are okay, replace alternator.

PARASITIC LOAD TEST

Note. Remove ignition key from cylinder before load testing. Key reminder circuit is activated by key cylinder switch when key is in ignition cylinder. This adds 20 milliamps of current draw.

1. Normal parasitic drain should be 6-10 milliamps. Turn ignition and all accessories off. Disconnect negative battery cable. On Sedan models, install an ammeter between negative battery cable and negative battery terminal so that ammeter is in series with other resistances. Read and record parasitic current drain from battery.
2. On Coupe models, install a jumper wire between negative battery cable and negative battery terminal. While jumper is installed, connect leads of ammeter to battery cable and negative battery terminal. This puts ammeter in parallel with jumper wire. After 10 seconds, remove jumper wire. Read and record parasitic drain from battery.
3. On all models, start removing fuses to find source of excessive load. When voltage drops across tester, circuit(s) protected by that fuse is source of current drain. Repair circuit and retest for parasitic drain. For normal parasitic load levelss, refer to the «NORMAL PARASITIC LOADS»(/saturn/sl/i-1990-1995/remont/charging-system/#alternator-regulator) .

NORMAL PARASITIC LOADS

BATTERY/ALTERNATOR LOAD TEST (ARBST TEST)

1. Clean battery terminals and attach ARBST load tester. Attach clamps to appropriate terminals. Clamp current probe to wiring going to negative battery terminal. Arrow on probe should point toward battery.
2. Press CHARGING SYSTEM TEST button. Display should show correct number of cylinders. To change number of cylinders, press appropriate button on keypad.
3. Run engine at 2000 RPM until display flashes MAINTAIN 2000 RPM. Hold at 2000 RPM until counter counts down from 10 seconds. When 10 seconds are over, run engine at idle until display flashes MAINTAIN IDLE.
4. Hold at idle for a few seconds until display flashes TEST COMPLETE. Turn engine off. Press CONTINUE button to see results of testing. ARBST tester will display voltage and current output of alternator.
5. With a good battery in vehicle, voltage output should be greater than 13 volts. All CS series alternators should be able to produce within 15 amps of rated output at 2000 RPM.
6. Sedan and Coupe models use an 85-amp alternator and should have a current output of at least 60 amps. If alternator does not pass voltage and current tests, ensure battery is fully charged and no excessive electrical loads. If battery and electrical loads are okay, replace alternator.

CARBON PILE LOAD ALTERNATOR TEST

Note. Ensure battery is fully charged when performing this test.

1. Install carbon pile load tester and voltmeter across battery terminals and clamp-on ammeter to one of the battery cables. Start engine and raise engine speed to 2000 RPM.
2. With engine at 2000 RPM, observe voltmeter. If voltage is uncontrolled or is greater than 16 volts, alternator is bad and must be replaced. If voltage is less than 16 volts, turn carbon pile load tester on.
3. While maintaining 2000 RPM, adjust carbon pile tester to obtain a maximum current reading on ammeter. DO NOT allow voltage to fall to less than 13 volts. If alternator output current is within 15 amps of rated output, alternator is good.

REMOVAL & INSTALLATION

Note. If necessary, remove power steering pump to access generator retaining bolts.

Removal

1. Disconnect negative battery cable. Using a box-end wrench, relieve spring tension from accessory drive belt tensioner. Remove accessory belt. Raise and support vehicle. Remove right front wheel. Remove right front wheelwell splash shield.
2. Remove generator splash shield. Disconnect field wires. Disconnect fusible link wire with Generator Output Stud Wrench (SA9401C) to hold generator output (B+) stud from rotating. NOTE: If stud is not held and stud rotates, plastic insulator will crack and/or break, causing generator failure.
3. Remove lower and upper generator mounting bolts. Remove generator through wheelwell opening behind strut. (Scheme 1)

Installation

To install, reverse removal procedure. Tighten mounting bolts to 24 ft. lbs. (32 N.m).

Scheme 1

Information is not available from manufacturer.

WIRING DIAGRAM

For wiring see apppropriate article

1. «WIRING DIAGRAMS»(ref-38609) (1991-92)
2. «WIRING DIAGRAMS»(ref-39175) (1993)

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• COMPUTER RELEARN PROCEDURES
• BATTERY/ALTERNATOR LOAD TEST (ARBST TEST)
• PARASITIC LOAD TEST
• NORMAL PARASITIC LOADS