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Thread: Electrical woes '96 Disco V8

  1. #1
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    Unhappy Electrical woes '96 Disco V8

    hi
    help!!!!can anyone help me cure this ailing disco
    i have a 1996 disco and i used to love it..........
    it is my second one as the first, i wrote off into a tree and kept the wreck for spare parts
    The issue i have is that the alternator light came on and then the car battery went flat over a few days of use. the tacho used to do a lot of bouncing at this time. i just assumed it was a dying battery. So.......
    1 One new battery did not cure the issue, next
    2 The old alternator out of the other disco, same model same year ok. No
    better.......
    3 next put new brush holder with new terminals into alternator. not fixed
    still
    4 Car now running with battery charger attached when parked for the night. tacho bounce and other weird crap going on
    5 then blew engine, not sure exactly what happened but rev tuning the motor (Driving and flogging it hard at the time probably did not help) the car had let me down too many times lately, and i thought i'd teach it a lesson. so now that engine makes funny noises and has positive pressure in rocker cover, when removing oil filler cap when running it blows fumes out
    6 changed out engine with other engine(dont ever want to do that again!) and got running
    7 no better electrically, then blew up ecu in less than a week. found burnt solder track on pc board. let me down yet again
    8 changed out ecu, running again. but still same electrically issue
    when car started cold it runs ok then plays up when warm but............
    this is not a hard and fast rule either. ocassionaly i can drive it for an hour or two and have no issues???????????
    9 i have now put a voltmeter and have been measuring output volatge.

    normal battery 12v approx
    running normal 13.8v approx
    it can then spike up to 16v two or three times second

    then drops down to 12vs and alternator light on and off, and tacho bouncing or staying at zero

    yet when running normal everything can be switched on.... headlights heater, wipers indicators radio ect....... with no draw down from the battery.

    then it fails and starts to draw power out of the battery.

    i have sometimes measured battery input volatge and current and found that the alternator may have 13.8 v output but only 3-4 amps to the battery. then when load switched on it draws the differance it needs from the battery. i.e total load = 10 amp 10-3 or 4 = -6 or 7 amps

    and even sometimes by switching the amp meter to ac amps, an ac current is overlaid over the top of the dc???? but thought that if an alternator diode failed it was fatal, perminent and clearly seen.

    i the measured the field excitation wire voltage from back of the instrument cluster and found it to vary from 11v odd up to 13.8v

    so i deduced it must be in the regulator part of the circuit.
    i also noticed that when i turn on the indicators the voltage dips about a half a volt to a volt on the gauge with each flash of the relay. could the voltage regulator be getting a voltage drop due to load in parallel with the reg affecting voltage supplying the reg????? things like the diff lock indication and associated switch, fuel gauge, thermostat ect..

    it appears to get its signal from the tacho/srs part of the cluster using a type of voltage divider.one fuse supplys this and a few other things as well .could this be where the cure is to be found...........

    i then changed out the instrument cluster.. no luck.

    i can only think of 2 things left to do......
    1 put in stand alone reg and use it to supply alternator excitation, a lot of thinking in that idea to take into account the tacho also gets its signal from there
    2 run a new supply with new fuse directly to the said components in the dash..... more heavy thinking

    i have stripped out any extra rubbish wiring from old radios, car phones, ect looking for the voltage drop. I read somewhere there a fusable links inside the wiring loom? I have fuses under the bonnet and in the dash i cant think why there would a 3rd set of fuses.

    i have just about had enough of this car
    i am at my wits end with it. I LOVE driving IT but fast losing patience with this problem. it began over 3 months ago. half of the dash is stripped out and internal plastics thrown into the back in desperation to fix this issue.
    thanks, AL

  2. #2
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    Al, did You check all ground lines?
    In TDI Discos the (-) goes from the battery direct in the chassis, and there is another cable between startes and chassis. Sometimes I hear that mechanics put a direct line between them, and then alternator, tacho and/or temp gauge electrical gremlins dissapear...

    Good luck
    Regards
    Last edited by German Grüner; 23rd August 2009 at 05:26 AM. Reason: spelling error!

  3. #3
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    Thanks very much for your help, it got me thinking so measured between the alternator and the battery earth and found +.5 volts the differance.
    I put a earth strap between them.
    still did not fix it, so started mucking around with the alternator. The new reg was differant from the old and i could not fit the capacitor next to the reg. so i did not put it in when i changed all those months ago.
    I thought that it may have been built in.
    So i thought i will just try and make the capacitor fit in. A bit of twisting made it fit
    and when put back together the problem was cured!!!!!!
    But...... I dont know what caused it in the first place as both alternators had capacitors. Also i swapped out regs and capacitors to start with and tested ok then. I really dont care now as it is working. Thank you, German Gruner for your reply as it helped get on the right track.

  4. #4
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    Oh i forgot i think maybe the problem may have been a faulty capicitor as the are used to smooth out ac ripple in this application as that which may come from an alternator. when load is switched in or out it may start voltage occillation up or down, so the signal going to the cpu causes the excitation voltage to swing like pushing a child on a swing, until it fails. I assume that the signal from the alternator needs to be a fairly pure dc voltage. This would explain the intermintant action of the tachometer. Then the failure of the voltage control would make sense. But i still cannot work out why i did not pick this up earlier.

  5. #5
    mike 90 RR Guest
    Far out ..Man

    That's a lot of thought that's gone into the solutions

    Personally tho ... Using a Alternator that came off a motor that been crushed by a tree would not have been my choice

    Mike

  6. #6
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    Some thoughts...

    If you were having such dramatic variation in voltage, it suggests to me that the regulator is NQR. You can have two problems at once, but it's usually a case of one before the other, possibly causing the other.

    The entire electical system should run off the alternator, not the battery. With everything on you should still have a voltage at the battery HIGHER than the float voltage of the battery without engine running.

    The tach signal is not rectified. It comes off one of the field coils only.

  7. #7
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    Quote Originally Posted by MacMan View Post
    Some thoughts...

    If you were having such dramatic variation in voltage, it suggests to me that the regulator is NQR. You can have two problems at once, but it's usually a case of one before the other, possibly causing the other.

    The entire electical system should run off the alternator, not the battery. With everything on you should still have a voltage at the battery HIGHER than the float voltage of the battery without engine running.

    The tach signal is not rectified. It comes off one of the field coils only.
    Hello
    I wish i had better electrical diagrams at the time to help me work out how the reg works and other stuff. I have now reread my last post and understand maybe i did not explain my self well. " I was thinking that maybe because the voltage was fluctuating so much it was upsetting the electronics supplying the regulator." Now that you have told me that the Tacho is not rectified. I wonder whether the absence of a capacitor allowed a rogue AC ripple to overlay what should have been a clean variable AC signal.

    It still appears to be fixed as i am running 600 watts of headlights (have a lot of wildlife where i live, wombats, roos and cattle) as well as all other circuits without missing a beat! I am very happy is an understatement!!!!!!
    p.s I changed out the regulator fairly early on in the problems with a new one ordered thru the local auto elec. At this stage i still have in service. So i thought i had cured the issue of the reg. I still really do not know what caused it nor can i really say with a definitave answer how i fixed it other than about 90% sure it was the capacitor help cure the issue
    Cheers alturbo68

  8. #8
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    Quote Originally Posted by mike 90 RR View Post
    Far out ..Man

    That's a lot of thought that's gone into the solutions

    Personally tho ... Using a Alternator that came off a motor that been crushed by a tree would not have been my choice

    Mike
    hi
    I will post a photo of the wreck soon, I hit the tree really hard and the airbags failed to go off, the srs light was up on the dash for about 2 weeks before and i thought "I must find out what that means". Well i did and it meant "the airbags aint gunna work" lol!!!! .
    So lesson learnt there! Seriously though i was fortunate that the motor was still able to run, and i drove it up onto a trailer. That motor is the new heart in my current disco. All the chassis is pushed sideways and broke an engine mount.
    If i hit that tree in a Holden "common dore", a Fraud "falcon" or other such car, i would be pretty messed up.

    The Disco's are pretty strong and i am happy to own one
    Cheers alturbo68

  9. #9
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    "That which can be done with fewer assumptions is done in vain with more."

    I think you've over thought all of this.

    You are overlooking the fact that your battery is the biggest and best capacitor that can be had, so to me it points the finger back at the alternator. Just because it's a different one does not mean that it is bad. Yhe only way you can test it is to take it to an auto electrician and have them spin it up on a growler. Until you KNOW that it is capable of delivering adequate voltage and current you're making a very large assumption that I would not be making.

  10. #10
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    so now that engine makes funny noises and has positive pressure in rocker cover, when removing oil filler cap when running it blows fumes out
    you sure that's not just normal crankcase breather air pumping out?
    There'll always be some degree of air being pumped up to the rocker covers, and with the engine running and oil splashing about its fairly common on any car to get oil (spray/mist) out of the filler cap.

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