Strangely, after the alternator upgrade, KGA has become a bit hesitant to start from cold. It turns over strongly enough and is happy to keep on turning, but it doesn't catch until the third or fourth attempt.
So new plugs, points, distributor cap and leads need purchasing, fitting and adjusting.
Monday 9 July 2007
Tuesday 3 July 2007
Improvements - Charging System - 23 June 2007
I settled on the 65 amp alternator from Scandcar. Only the 35 amp version is listed as suitable for a '66 121, but they confirmed that the 65 amp version would fit. They were right, but it was a very close call...
The amp is Scandcar part number 79910211 , but (despite the picture) you need to order the bracket separately, number 419417. It all came within a few days of ordering, along with a new fan belt and thermostat.
Instructions came in Dutch... But with the help of a chum who speaks Afrikaans ,we got as far as "thick black wire to B+" and "thin red wire to D+", which corresponded to the wires going in to the old voltage regulator and the terminal names on the new alt.
The job basically involves disconnecting and removing the dynamo, unbolting the original mounting bracket, fitting the replacement mounting bracket, bolting on the alternator, unplugging the two wires going into the voltage regulator and connecting them to the alt. The alt has its own regulator, so the old one can be removed - which I did once the alt had proved itself.
This is how the connections looked beforehand:
Removing the dynamo and the spare wires was a five-minute job, and the new bracket went on without any issues:
But after that things got trickier. The 65 amp unit is a very tight fit and there's not much room for adjustment to get the fan belt on or make it taught. Initially I could only get the old slack belt to fit, but there wasn't room to tighten it without the alt fouling the steering box. The shrieking noise wasn't much fun, so it came off and the new belt went on.
After much heaving, groaning and head-scratching, the very last trick got the new belt on. It involved loosening the new bracket so it hung off and could be freely moved, putting the belt on the alt and bolting the alt to the bracket. Then gradually tightening the bracket until it was securely in place, bringing the alt into line and the belt nice and tight:
The amp is Scandcar part number 79910211 , but (despite the picture) you need to order the bracket separately, number 419417. It all came within a few days of ordering, along with a new fan belt and thermostat.
Instructions came in Dutch... But with the help of a chum who speaks Afrikaans ,we got as far as "thick black wire to B+" and "thin red wire to D+", which corresponded to the wires going in to the old voltage regulator and the terminal names on the new alt.
The job basically involves disconnecting and removing the dynamo, unbolting the original mounting bracket, fitting the replacement mounting bracket, bolting on the alternator, unplugging the two wires going into the voltage regulator and connecting them to the alt. The alt has its own regulator, so the old one can be removed - which I did once the alt had proved itself.
This is how the connections looked beforehand:
Removing the dynamo and the spare wires was a five-minute job, and the new bracket went on without any issues:
But after that things got trickier. The 65 amp unit is a very tight fit and there's not much room for adjustment to get the fan belt on or make it taught. Initially I could only get the old slack belt to fit, but there wasn't room to tighten it without the alt fouling the steering box. The shrieking noise wasn't much fun, so it came off and the new belt went on.
After much heaving, groaning and head-scratching, the very last trick got the new belt on. It involved loosening the new bracket so it hung off and could be freely moved, putting the belt on the alt and bolting the alt to the bracket. Then gradually tightening the bracket until it was securely in place, bringing the alt into line and the belt nice and tight:
The final issue was bolting the alt to the top adjustment bracket. It wouldn't fit around the edge of the alt so I've fitted a secondary bracket in between. This holds solid and allows free adjustment and should by no means be considered a bodge:
And KGA is far far better for it. The old regulator can't have been up to much - with the alt the engine runs more smoothly and the fuel gauge fluctuates less wildly. The charging warning light never comes on, even at idle, and the indicators still work even with the lights, wipers and heater on.
After a trouble-free 200 mile round-trip to Silverstone I checked and tightened all the new fixings and connections. The alt's been fine and comes as a highly recommended enhancement. But unless you really need the extra power, a 35A unit would be a far easier option.
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