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PostPosted: Sat Feb 03, 2007 11:52 am 
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Joined: Tue Mar 16, 2004 8:55 am
Posts: 11264
Location: Geelong, Victoria
Wiring Modification from Generator to Alternator. On Early Mini.



Disconnect and remove battery from car. Remove generator from engine. Familiarize yourself with the terminal configuration and markings on terminals on the new Alternator. It will be easier to look at them now than when it is bolted in the car. If necessary make a sketch of the terminals . Replace the rear mounting bracket bolted to the front of the engine block that the Generator was mounted to with the proper bracket from an Alternator equipped Mini. (This is longer and will also accommodate the Ignition coil) If you do not have access to one of these brackets you will need to use a much longer bolt and lots of spacers to make up the distance. Finding a proper bracket makes the job easier and the finished result neater. Fit new Alternator using same bolts and nuts. Might help and makes it easier also to slip the pulley under the belt before you fit bolts. When all in place, adjust belt to correct tension and tighten all bolts.

Before removing the Voltage regulator Mark all wires with the corresponding letter of the terminal they are on. Using proper Joiners that can carry high current join together the wires that were on terminals A1, A and D except the smaller wire that was on terminal ‘D’, It connects to the wire that came off terminal F. Leave the E wire out and just tape it op out of the way. So you only end up with two connections. Personally I like to solder these wires together, insulate them well with electrical tape and also hide them neatly in the harness itself. Now at the alternator end you have the two wires large and small. Connect the small wire to the D+ terminal of the Alternator which is the smaller one of the three large Spade pins and the larger wire to any of the other two large spade terminals marked B+. When fitting an Alternator of higher output it is advisable to add an extra wire (6 mm at least) from the B+ terminal on Alternator to the “battery” side of the starter solenoid. This you can either connect to the remaining large Spade terminal on Alternator. This wire is needed in this case as the original wiring to generator is no where near capable of carrying the charge the alternator can produce. When all the wires are zipped out of the way and all is in place Re fit battery back in Battery box and make sure it goes in with the positive terminal towards the front of the car. Re fit battery hold down clamp. Connect battery with Negative terminal to Earth (Ground or Chassis) When you connect the last terminal make sure there are no sparks.

That should be it. Turn Ignition Key on and you should have ignition light and when you start the engine up light should go out. Note that the Warning light does not come back on when engine revs drop to Idle speed as an alternator is capable of charging at lower RPM unlike the Generator.

If in Doubt consult a Professional Auto Electrician. Remember if you let the smoke out of the wiring, nothing will work and it is very expensive to repair and replace the smoked out wiring.



Tony Buttigieg.

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