Battery Light On

nc-grayson

Member
Greetings All,

I hate to start a new thread about a similar topic to something I asked a week ago, but I think it's time as now my issue has digressed from the original problem, and we're kinda on a new topic here, so for future searching, Im making a new thread as opposed to tacking on my old one:

http://www.toyota-4runner.org/3rd-g...r-replacement-mounting-bracket-questions.html

Long story short: I replaced my dying parts store reman'd CS-144 upgrade with an OEM denso alternator I pulled out of the pick & pull for $13. I foolishly traded my oem denso in at the time of the CS-144 upgrade as a core deposit.

First things first, I had the denso i pulled from the p&p bench tested at autozone and it passed with flying colors.

Installed the new to me denso, and everything is kosher. Except for the fact that my battery light is now on on the dash. Not flickering, not intermittent, just on 24/7.

The only difference between today and when my dying CS-144 was installed is the actual difference in alternators as well as the electric plug. I had bought the harness/pigtail for the CS-144>toyota swap, so as to not hack and splice oem wiring. I simply removed this harness, and clipped the OEM connector into my new (used) OEM alternator. That's it.

And now the battery light is on.

I had to drive 45 miles yesterday with the battery light on. The numbers below are representative of when I got home, AFTER the 45 mile round-trip with the battery light on.

Resting with the engine off, the battery is putting out 12.86 volts, (again, AFTER a 45 mile trip, so I assume the alt was charging the battery those 45 miles even with the light on)

With the engine on, the battery is pushing 14.2 volts at idle, so I'm using those numbers in conjunction with the numbers at the parts store when they bench tested the alt to assume that yes, in fact, the alt is charging.

So why is my battery light on?

I've tested all of my connections, and they're sound. I've upgraded to the BIG 3 already, and all of those connections checked out as well. Fuses, included the 120 amp fusible-link alt fuse, are all tested and good.

is it possible for the new-to-me denso to pass the bench test with flying colors, put out 14.2 volts when running, AND STILL cause the battery light to come on?

Can an alt *appear* to pass every test on the bench and installed, yet still cause the battery light to come on because of worn brushes, IC regulator, or rectifier?

Literally the only difference between the two setups I've had is the CS-144 alternator and the aftermarket harness swapped back to OEM parts, and the addition of my battery light on the dash illuminated.

Kinda at a loss here.
 
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I've tested all of my connections, and they're sound. I've upgraded to the BIG 3 already, and all of those connections checked out as well. Fuses, included the 120 amp fusible-link alt fuse, are all tested and good.

Does that include a good inspection/cleaning of the positive battery terminal and wire?
 
Does that include a good inspection/cleaning of the positive battery terminal and wire?

yes. All of the wiring, battery, terminals, and connectors have been checked, visually, and with a multimeter. The wiring, battery, terminals, and connecters were all re-done less than a year ago when I upgraded to the Big 3.


I have seen all of those threads in my searching this morning, thank you however.

I'm still a bit uncertain if an alternator can bench test and pass with flying colors and still have internal issues either with brushes, regulator, or rectifier.

Thank you
 
The pins are clean on the back of the junkyard alt? It seems the regulator in the alt isn't sensing that it's charging..........


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I only had my battery light come on once in 17 years & that's because my alt was failing. That old $13 alt you bought will probably get you stuck somewhere.
 
Bumping this because 3 weeks later I've still got the same light on. FWIW I've driven over 1800 miles in those 3 weeks, and my battery is still sitting around 12.85V with ignition off.....so it's definitely charging.

Today I finally replaced the $13 p-n-p denso with a reman'd denso from RockAuto, and I still have the light. Made some comments below these post-quotes....I'm guessing the only culprit I should focus on would be the OEM connector at this point....or start there at least? I just don't understand how returning completely to stock gives me grief when aftermarket crap seemed so straight-forward.


The pins are clean on the back of the junkyard alt? It seems the regulator in the alt isn't sensing that it's charging..........
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This was my thinking exactly.

Yes, they were. I cleaned the crap out of those and the oem harness with electrical parts cleaner, and the battery light was still there.

Not that that means anything now as I've replaced the $13 denso with a reman'd one.

I only had my battery light come on once in 17 years & that's because my alt was failing. That old $13 alt you bought will probably get you stuck somewhere.

I agree with everything you're saying....I'm still stumped :(

Luckily for me the old $13 denso held up to it's name for the past 3 weeks and 1800+ miles.


What are the odds my $13 p-n-p denso and my $150 reman'd denso from rock auto both have busted voltage regulators?
 
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What's the battery voltage when running?

Maybe the 7.5A "ALT" fusible link went bad? That is the connection that the alternator uses to detect battery voltage - if disconnected, it would light the dash light.

-Charlie
 
What's the battery voltage when running?

Maybe the 7.5A "ALT" fusible link went bad? That is the connection that the alternator uses to detect battery voltage - if disconnected, it would light the dash light.

-Charlie

voltage when running is 14.0+ , same with the $13 denso and the $150 denso.

I checked that fuse 3 weeks ago, (I remember checking it, but cant remember if I'd put the dmm to it or just visually), so I'm going to check into that now and report back.
 
mother of god it was the 7.5 Alt-S fuse the whole damn time. Beers for [MENTION=139000]phattyduck[/MENTION]. I'm embarrassed.
LESSON LEARNED: Sometimes, the simple solution is the answer. Double, triple check your fuses. Don't waste your time, (and everybody else's), on something as simple as a damn fuse. It's very easy to get overwhelmed when simple shit stumps you. KISS.
 
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voltage when running is 14.0+ , same with the $13 denso and the $150 denso.



I checked that fuse 3 weeks ago, (I remember checking it, but cant remember if I'd put the dmm to it or just visually), so I'm going to check into that now and report back.



It's interesting your alt appeared to be charging and operating normally with that fuse blown. My electrical drawings are at my garage.......to see what that fuses job is


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It's interesting your alt appeared to be charging and operating normally with that fuse blown. My electrical drawings are at my garage.......to see what that fuses job is


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Right? You'd think after 1800 miles and 3 weeks, if the alt wasn't charging and operating normally, I'd have been stranded by this point no?

I'll dig out the EWD and take a look.

My thought process is that I overlooked the 7.5 amp fuse. I've blown the 120amp main fusible link before by grounding the CS-144 alt post against the larger oil filter like a moron. (part of the reason I switched back to OEM.....much more room for the larger YZZD3 Filter). So I pulled the fuse box apart and visually inspected and tested that 120 amp fuse, and I guess I just stupidly overlooked the smaller 7.5 amp alt-s fuse.

It's got me thinking now...At, (or around) the same time, I disconnected my subs in the back to move some bulkier items around. When I reconnected them, they didn't want to....bump. I could feel them moving with minor vibrations with regular music, and the amp checked out fine.

I wonder if that 7.5 amp alt-s fuse goes down the line of some audio functions.

EWD here i come
 
Don't know if you fixed this but I believe there is a "sensor" wire that can have something wrong with it (not sure if it having been cut or open and grounded etc) but it can cause that lift to come on, good luck on getting it fixed if you haven't already!
 
Don't know if you fixed this but I believe there is a "sensor" wire that can have something wrong with it (not sure if it having been cut or open and grounded etc) but it can cause that lift to come on, good luck on getting it fixed if you haven't already!

He fixed it bro.
 
This goes inline with the almost pristine 97 I test drove, paid for, then didnt get 10 miles away til it completely died on me with a brand new battery.

We looked at the 100A fuse, the 7.5A fuse, etc...and still couldnt figure out why the battery light was on and it wasnt charging. truck was surging if you applied any kind of gas to it.

Owner said the new alternator was only a couple years old.....but who knows. Whatever that drain was killed a BRAND NEW battery in the span of 30 minutes.

Luckily for me he was a stand-up gentleman and we cancelled the bargain for the truck and I wasnt stuck 150 mi from home with it.
 
This goes inline with the almost pristine 97 I test drove, paid for, then didnt get 10 miles away til it completely died on me with a brand new battery.



We looked at the 100A fuse, the 7.5A fuse, etc...and still couldnt figure out why the battery light was on and it wasnt charging. truck was surging if you applied any kind of gas to it.



Owner said the new alternator was only a couple years old.....but who knows. Whatever that drain was killed a BRAND NEW battery in the span of 30 minutes.



Luckily for me he was a stand-up gentleman and we cancelled the bargain for the truck and I wasnt stuck 150 mi from home with it.



But, his rig appeared to be charging and maintaining the battery with the battery light on.........


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I know this is an older thread but I’m have the same issue .Alternator is passing every test as so the battery .The key in the on position the alternator plug reads red/blue wire 12.53, white wire 12.53, yellow/green wire 4.34. I can confirm the battery light comes on when the plug is plugged back into the alternator. I’ve checked the fuses with a continuity tester ,I’ve checked the grounds , so far I’ve pulled my dash apart and my fuse box open and haven’t seen any obvious broken links .Im not good with wires so any help is greatly appreciated..What would cause the wire that feeds the light to only have 4.34 volts and what wire in the ignition controls it ?
 
I know this is an older thread but I’m have the same issue .Alternator is passing every test as so the battery .The key in the on position the alternator plug reads red/blue wire 12.53, white wire 12.53, yellow/green wire 4.34. I can confirm the battery light comes on when the plug is plugged back into the alternator. I’ve checked the fuses with a continuity tester ,I’ve checked the grounds , so far I’ve pulled my dash apart and my fuse box open and haven’t seen any obvious broken links .Im not good with wires so any help is greatly appreciated..What would cause the wire that feeds the light to only have 4.34 volts and what wire in the ignition controls it ?

The 1996 Yellow/Green wire goes from the bat light directly to the voltage regulator. So if your getting 4.34 at the alt and your dash.. It is kinda leaving the voltage regulator that is inside the alternator. :-( Must be starting to go bad..
 
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The 1996 Yellow/Green wire goes from the bat light directly to the voltage regulator. So if your getting 4.34 at the alt and your dash.. It is kinda leaving the voltage regulator that is inside the alternator. :-( Must be starting to go bad..

I’m getting 4.34 from the pigtail side ,its not plugged into the alternator minus the cable going to the stud ..I have continuity from dash plug to alternator plug

Dash plug black /white wire to ignition switch black /red wire continuity

The ignition switch on the back of the tumbler is in line with all this could it be a back switch (switch has continuity on all the points)
 

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