REMY QUICK TECH TIP TA-040: Numerous charging problems

VEHICLES AFFECTED:
1980-1984 Volvo 240 Diesel
1983-1986 Volvo 760 Diesel
1985-1986 Volvo 740 Diesel

SYMPTOMS:
Numerous Charging Problems

CAUSE:
Volvo TSB Group 32, NO. 1 advises that the above vehicles have been shown to have a poor ground connection between the alternator and the engine block causing problems in the charging system.

SOLTUION:
An additional ground cable (Volvo #1215278-1) should be attached to the back of the alternator and connected to the alternator block mounting bracket.

REMY QUICK TECH TIP TA-039: High RPM belt whine/noise

VEHICLES AFFECTED:
1988-1992 Jaguar XJ6, XJS

SYMPTOMS:
These vehicles may exhibit high RPM belt whine/noise.

CAUSE:
This condition may be caused by an over tensioned belt.

SOLUTION:
XJ6 Models: Make sure the belt tension is set to 115 lbs. for a used belt or 138 lbs. for a new belt.
XJS Models: Make sure the belt tension is set to 70 lbs. for a used belt or 79 lbs. for a new belt.

REMY QUICK TECH TIP TA-036: Pulley sizes vary on different models

VEHICLES AFFECTED:
1976-1983 Honda

SYMPTOMS:
Alternator Pulley

CAUSE:
Pulley sizes vary on different models using the same alternator.

SOLUTION:
On some vehicles it may be necessary to replace the pulley provided with this alternator with the pulley from the original alternator. Check the spacing of the pulley groove from the alternator fan. If the spacing is different, change the pulley to ensure proper belt alignment.

REMY QUICK TECH TIP TA-035: Stereo cassette radios may experience alternator whine in the left channel of the radio

VEHICLES AFFECTED:
1986 – Chevy Astro Van
1986 – GMC Safari Van
1986 – S/T 10-15

SYMPTOMS:
Some above listed models equipped with ETR AM/FM stereo cassette radios may experience alternator whine in the left channel of the radio.

CAUSE:
The ground wire used in the instrument panel harness may cause a ground loop resulting in the whine.

SOLUTION:
If this condition is present, disconnect the ground lead (black wire) from the black 4-pin connector at the back of the radio. If disconnecting the ground lead causes the condition to disappear, proceed as follows:
1. Cut the black ground wire located in the black 4-pin connector
2. Connect one end of a suitable gauge wire to chassis of the radio and the other end to a good ground near the radio.
3. Reconnect the radio.

REMY QUICK TECH TIP TA-034: Serpentine belt chirp or excessive belt noise

VEHICLES AFFECTED:
1999-2003 Land Rover Range Rover
1999-2003 Land Rover Discovery

SYMPTOMS:
Serpentine belt chirp or excessive belt noise.

CAUSE:
The plastic idler pulley may be deformed causing uneven loads on the serpentine belt.

SOLUTION:
Replace deformed idler pulley with Land Rover part # (PQR500060).  Refer to Land Rover TSB #86/02/03/NAS for further information.

REMY QUICK TECH TIP TA-033: Accessory drive belt squealing or drive belt jumping off the pulleys

VEHICLES AFFECTED:
2001 Chrysler Town & Country
2001 Chrysler Voyager
2001 Dodge Caravan

SYMPTOMS:
Accessory drive belt squealing or drive belt jumping off the pulleys.

CAUSE:
It is possible water may drip down from the wiper module drain tube connector and onto the drive belt.  This may cause belt squealing.  In colder regions, ice can form on the belt and cause the belt to jump off the pulleys when starting the vehicle.

SOLUTION:
Find the wiper module drain tube near the top of the right strut tower.  With the hood open, send water into the cowl grille.  If water is leaking at the wiper drain tube connector, install a new seal (05080824AA) as outlined in Chrysler TSB# 23-012-01.

REMY QUICK TECH TIP TA-032: Malfunction Indicator Lamp may come on due to Diagnostic Trouble Codes being set for abnormal conditions which may or may not actually exist

VEHICLES AFFECTED:
2003 Chrysler 300
2003 Chrysler Concorde
2003 Dodge Intrepid

SYMPTOMS:
The Malfunction Indicator Lamp (MIL) may come on due to Diagnostic Trouble Codes (DTC’s) being set for abnormal conditions which may or may not actually exist.  One example is DTC # P0622: “Alternator Field Not Switching Properly.”

CAUSE:
A software glitch may exist in Powertrain Control Modules built prior to 10-15-02.

SOLUTION:
Refer to Chrysler/Dodge TSB# 18-032-02 for instructions to selectively erase and reprogram the Powertrain Control Module (PCM) to the latest version.

REMY QUICK TECH TIP TA-031: Battery warning light/overcharge condition

VEHICLES AFFECTED:
2001-2003 Chrysler Town & Country Van
2001-2003 Chrysler Voyager
2001-2003 Dodge Caravan

SYMPTOMS:
On some vehicles, the battery warning light may come on and an overcharge condition may occur.  Also, a DTC code of P1594 for “Charging System Voltage Too High” may set in the vehicle’s computer.

CAUSE:
Since this type of alternator contains no voltage regulator (the vehicle’s computer performs all voltage regulation), the Powertrain Control Module (PCM) may require reprogramming.

SOLUTION:
Check for usual causes of overcharging (corroded connections, poor ground, older/defective battery).  If no obvious cause, refer to Chrysler / Dodge TSB# 18-023-03 for instructions for selectively erasing and reprogramming the PCM with updated software.

REMY QUICK TECH TIP TA-030: Low Alternator Output

VEHICLES AFFECTED:
1988-2007 Honda

SYMPTOMS:
Low Alternator Output.

CAUSE:
The above vehicles may be equipped with an Electronic Load Detector (ELD) located in the under-hood fuse/relay box.  The ELD monitors vehicle load demands and signals the power control  module.  During low electrical current demand, the ELD/PCM switches the alternator to low output mode (12.5 volts) through the alternator’s “C” terminal.

SOLUTION:
Voltage will register approximately 12.5 volts when the alternator is in low output mode.  When testing the alternator it is advised that the brake pedal be applied, which causes the ELD to signal for normal alternator output (14-15 volts).

If the voltage remains low during the above test, the ELD/PCM may be at fault.  To test, remove the “C” terminal from the 4 pin alternator plug by releasing the locking tab with a thin bladed screwdriver.  Reinstall the plug (with “C” terminal removed) and retest.  If the alternator now tests normally the ELD/PCM should be tested and serviced by a qualified technician.

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