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Battery not charging
#1
Hi fellow Berlingers

I’ve just wrestled the Bosch alternator off my ‘07 M59 1.6hdi - got the bleeding knuckles to show for it (usual production line design with no interest in maintainance)!
I was getting a battery light and discovered that there was no charge voltage so thought I would take a butchers before the wallet got a wringing. I see online that rectifier sub-assemblies and also the outer regulator & brush module are readily available so thought I might save some increasingly elusive wonga. Trouble is everything looks fine, so I thought I would ask the forum if anyone can speculate on the possible problem part, or advise on how to test – perhaps you may know a good info link. I’m just going to assume that the stator and rotor coils are ok – a rewind is a step too far and want to focus on the rec & reg.

…..cheers

'07 600x 1.6HDI 75 Berlingo (M59) short van
RPO: 11251
Engine: DV6B Gearbox: BVM5 BE4-5L
Confusedtudy: MK2 1.6HDi 75 short van '600' M59
'07, 80k
DV6B Engine
BE4-5L manual gearbox
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#2
No replies, but I notice a few viewing so I have attached some alternator info that I have found to date, in case it is useful to anyone.

Happy motoring!

'07 600x 1.6HDI 75 Berlingo (M59) short van
RPO: 11251
Engine: DV6B Gearbox: BVM5 BE4-5L





Attached Files
.pdf   Alternator infos.pdf (Size: 1.58 MB / Downloads: 30)
Confusedtudy: MK2 1.6HDi 75 short van '600' M59
'07, 80k
DV6B Engine
BE4-5L manual gearbox
[-] The following 1 user says Thank You to Tenere for this post:
  • Andre
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#3
That is an excellent document Tenere, thanks.
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#4
Big Grin 
(26-11-2011, 02:37 PM)Andre Wrote:  That is an excellent document Tenere, thanks.

Thanks for that Andre, appreciated mate. I've just updated that PDF with a little more info. Basically the M59 circuit diagram - damned if I can follow it, too many mystical black boxes! I remember when a van diesel didn't need any electrics bar the heater plugs or a damn good push!

Anyway, I gave up and got a salvaged alternator from Ebay - £25 delivered and a nice one, so can't complain there. Not looking forward to the grazed knuckles and swearing bit though! Just hope it sorts the problem and I don't need a NASA technician with a sonic screwdriver for mystical box repairs!

Confusedtudy: MK2 1.6HDi 75 short van '600' M59
'07, 80k
DV6B Engine
BE4-5L manual gearbox
Reply
#5
(26-11-2011, 02:31 PM)Tenere Wrote:  No replies, but I notice a few viewing so I have attached some alternator info that I have found to date, in case it is useful to anyone.

Happy motoring!

'07 600x 1.6HDI 75 Berlingo (M59) short van
RPO: 11251
Engine: DV6B Gearbox: BVM5 BE4-5L

Cheers mate, most helpful.
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#6
as you can see item 1020 is the alternator, with the output going direct to the battery, its a standard unit with 3 phase rectifier pack which you cannot test without breaking it open and measuring the diodes individually. The voltage regulator reads the voltage and adjusts the field coil to keep the output at or below 14.4v under a variety of loads. If the brushes are not good then the field coil will be low, leading to low or no output.

The field is supplied by the battery charge light from the ignition 12v circuit and when up to charging speed the bulb gets 12v at both ends, extinguishing it and showing the alternator is working...so the brushes could be bad, a diode failed in the rectifier pack or the VR has failed and cut the output off. Try pulling the VR/Brush pack off a scrap car and see if that cures it? Alternatively you may be able to get it repaired by an alternator repair shop (most faults are the rectifiers & VR units anyway, windings rarely fail)
My Van: 2007 1.6 HDi 600 - currently on 62,000 miles  Sleepy
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