"service manual"
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1. auto repair can replace their original Lucas 25ACR 65 Amp alternator with a newer 96 Amp alternator from Bosch the same alternator supplied to GM s Saturn product line The higher current output at low engine RPMs from the Bosch alternator will prevent the TR7 s interior and exterior lights from dimming and getting brighter as the engine goes into idle or as the RPMs increase from idle Another Reason for Upgrading To A Higher Current Alternator Later after replacing the alternator I added up all the electrical current loads on my particular TR7 and I wasn t surprised the original Lucas alternator became defective If the original alternator was capable of 65 Amps of current continuously I was using the alternator close to or beyond its specifications By adding up the electrical current demands on my vehicle the newer 96 Amp alternator supports my vehicle s needs much better During day time operation if I just take a reasonable guesses at my car s typical electrical current demand my TR7 typically wants about 23Amps from the alternator electric radiator fan 12A intermittent duty radio CD Player about 2A EFI fuel pump 15 10A are mS duration pulsing injectors 7Amps average Ignition 6A pulsing about 2 Amps time average battery recharging variable amount At night add in 40 Amps to 47 Amps more Head Lamps 10A 55W each on low beam day time use in some countries Hi Beams 17A intermittent duty side trim2. Triumph TR7 Saturn Bosch Alternator Upgrade Greg Bober Copyright 7 Sept 2008 Rev 1 2 originally written 4 Sept 2005 The following information is presented as public knowledge and is only for the personal use of individuals who are either restoring or repairing their own Triumph TR7 vehicle The information may not be used commercially without the consent of Greg Bober the author who can be contacted via gl4legs comcast net Triumph car clubs can reprint this as a monthly newsletter article but please email gl4legs comcast net so I know where in the world this has being reprinted Thanks Abstract After 25 Years and 101 000 miles something in my TR7 s alternator broke It was no longer providing any output current Its possible that one or two or more diodes in the alternator s rectifier had become non conductive Locally its getting hard to find parts service for older British cars some auto parts stores don t even recognize that Triumph was a company that made cars just like Nash At this time I planned on driving and putting my TR7 on display at the Detroit Triumph Sports Cars and Motor Cycle Show the car show was 7 days away Obtaining a replacement alternator or replacement parts from another state or the UK would mean that my TR7 would miss the 2005 car show The circumstances forced me to locate a suitable equivalent replacement for the Lucas 25ACR alternator This document describes how a person with a limited skill in
3. and dashboard lamps 15 fog or driving lamps 15 Add another 15 Amps to support intermittently used vehicle features Windscreen Wipers 10A intermittent duty A C clutch 5A intermittent duty interior blower 10A not used too often is a Drop Head Coupe brake lamps 6A intermittent duty turn indicators 5A intermittent duty If everything is activated at the same time all of these add up to a worst case demand of about 110Amps Such a worst case condition doesn t happen often but it is possible and not continuous Should such a condition occur the alternator will be able to supply 87 of the vehicle s needs The remaining 13 power demand will be sourced from the car s battery Prior to the installation of the higher current alternator the Lucas 25ACR alternator covered only 60 of the maximum demand and during my typical night time operation the Lucas 25ACR was often operating at 100 of its capacity with no reserve capability support intermittent duty vehicle functions This is 1 reason why my interior and exterior lamps would dim when the engine idled and I pressed the brake pedal Read this First Read all instructions before starting the repair procedure Tools Required e screwdrivers pliers Clamp wire cutters wire strippers wire connector crimping tool 10mm socket wrench 12 5mm or socket wrench and wrench Replacement or Upgrade Components Required The components are avai
4. e in the automotive industry they prefer to call that particular piece of sheet metal the cowl panel 2 diameter belt pulley with 0 67 shaft hole from a Ford Motor Craft alternator At my local AutoZone store I was given one of these pulleys for free from a smashed returned alternator core These pulleys were used on almost all Ford US amp Canadian vehicles from 1975 to about 1990 No part number 15 available A Ford pulley isn t mandatory But you ll definitely need a 2 5 to 3 6 diameter pulley with a 0 67 shaft hole so there is flexibility in what can be used see Appendix B The Lucas alternator s pulley can not be reused because its shaft will not fit properly on the Bosch alternator s shaft 85854 Alternator pig tail harness 7 from AutoZone East Pointe MI This same pig tail harness from a Saturn dealer was quoted at 43 sleeved male 4 wide spade terminal connector male and female sleeved barrel terminal connector I wanted these connectors to be different to avoid any chance of misconnection and be sleeved with a protective coating to avoid touching any metal surface which would cause a short circuit Alternator Removal From Vehicle Reference TR7 Service Manual page 389 Procedure 86 10 02 Safety First Before starting disconnect the car s battery terminal and fold it under the battery tray to insure an electrical connection or short is not accidentally made during t
5. he vehicle s servicing These instructions are unique relative to my EFI type TR7 but would be similar for the carbureted version of the TR7 These instructions have been re sequenced from the original discussion room s posting l Remove the air by pass hose that connects from the by pass valve located almost above the alternator and hose from the intake plenum to the top of the charcoal canister Fold these hoses back and out of the way Remove upper adjustment bracket bolt supporting the top mounting ear of the alternator Disconnect electrical connections from the rear of the existing Lucas alternator Disconnect the lower mounting bolt thru the Lucas alternator s lower mounting holes When removing this lower bolt be prepared hold the 10 Lbs alternator Loosen and fold up the upper mounting bracket out of the way and as far back as possible Lift and remove the old Lucas alternator from the engine compartment See Picture 1 Picture 1 Old alternator removed from engine mounting brackets Te 8 9 10 11 12 13 14 15 On the 85854 pig tail harness cut amp remove black wire Itis not needed Cut it at the base of the connector so that nothing can accidentally short against this particular wire Cut the red and brown wires 3 inches or 75mm long See Picture 2 and 3 Crimp a barrel shaped terminal on the Bown pig tail harnesses wire Crimp a mating barrel shaped connector on the Brown Yellow wire i
6. isconnected in Step 1 Reconnect the battery cable connection s at the battery s terminal Testing the New Alternator e Start the vehicle and measure the voltage applied to the battery with little electrical loading headlamps and all other vehicle features OFF The 8215 alternator on my vehicle was applying 14 7V across the battery s terminals e Check the instrument panel s Volts gauge the meter s pointer should be located near the maximum normal or white zone demarcation see Picture 7 Picture 7 TR7 s Voltage Meter pointer location showing the Alternator is charging the battery Done Pat yourself on the back and go for a road trip Other Reference Documentation 1 TR7 Service Manual AKM3079B Published by BL Car Limited 1981 2 3 4 web site reference removed due to accuracy issues Appendix A information 5 Bosch USA Customer Service is the source for the AL8596 alternator technical data Biography Sorry can t find a picture of me I m always holding the camera so here s my TR7 I ve been a part of designing automotive electronics since joining Ford Motor Co North America Automotive Components Division now Visteon in 1986 my credit I ve designed the control electronics for many different suspension steering control modules body illumination modules dash panel clocks and multi gauge instrument clusters examples are Thunderbird Super Coupe Shock and Steeri
7. lable from common Auto Parts in the United States and from internet auto parts web sites Some can even be obtained from junk scrap yards e GM Delco Remey 8215 Alternator used on US Canada GM Saturn L Cars with a 1 9L gas engine from 1991 to 1996 some auto parts web sites indicate 1991 to 2002 Model Years See Appendix A for a listing of other equivalent part numbers for this alternator The 8215 Alternator is actually a Bosch unit and is available from many auto parts stores and internet auto parts suppliers The 8215 Alternator is a little smaller than the Lucas 25ACR alternator but it fits into the TR7 without having to make a bracket or need for any special tools I purchased mine as a rebuilt alternator 100 from George s Auto Parts in St Clair Shores MI it looked clean and new out of the box For price comparison A local Saturn dealer wanted 150 for a new alternator A local scrap salvage yard wanted sell this alternator for 35 but it was in a dirty used and untested condition Be warned if you are going to salvage a Saturn car your self the alternator is located on the under side of the engine against the passenger side cowl panel and near the exhaust manifold a rather in accessible location without a car hoist PS Automotive people don t call it the firewall anymore since it really can t prevent a fire from penetrating into the passenger compartment Thus thos
8. n the TR7 that used to connect to the rear of the Lucas alternator Crimp a sleeved male spade terminal connector on the Red wire of the pig tail harness The pig tail harness should appear as shown in Picture 3 Remove the modern 5 groove belt pulley from Bosch 8215 alternator replace it with the 2 5 or 2 5 to 3 6 diameter V belt type pulley from another alternator An auto parts store or alternator refurbishing shop can assist you in accomplishing this task With a clamp squeeze the mounting insert on the Bosch 8215 alternator deeper into its mounting hole as deep as possible the extra is all my new alternator needed to fit the alternator into my TR7 Depending upon fit in your vehicle this may not be required See Picture 4 Plug the little harness made in Steps 7 through 12 into the socket located in the back of the Bosch 8215 alternator See Picture 5 maintain existing Large Brown 6G TR7 Battery Cable and eyelet back of Bosch 8215 alternator existing TR7 small 18G Brown wire and with male spade terminal trim Red wire to 3 or 75mm length cut black wire against the 85854 connector existing TR7 Brown Yellow 18G wire crimp on a matching set of connectors for these wires trim Brown wire to 3 or 75mm length Picture 2 Bosch 8215 Alternator to TR7 wiring diagram through the 85854 pig tail harness Picture 3 The 85854 Pigtail harness Black wire removed amp connectors c
9. ng module Lincoln Mark 8 Shock Module Jaguar XJC clock Jaguar 5 Class cluster Lincoln LS cluster Nissan Quest Mercury Villager cluster plus many more over 20 years From 2005 to 2008 I briefly worked at the Alternator Wiper Fuel Pump lab at the Ford ACH Visteon Rawsonville MI plant and at the HVAC lab at the Sheldon Rd plant From 2002 to 2005 I restored the above California EFI type TR7 Spider using many methods of improvement applied to current production vehicles for electrical power distribution and fusing strategies My TR7 now has reliability similar to a new car I sometimes drive it to work 70 miles round trip I now design and test Lithium Ion battery packs for the next generation electric hybrid vehicles Appendix A Table of Equivalent Alternators According to a few auto parts interchange web sites the alternators listed below are equivalent replacements Be very careful databases can t always be trusted to be accurate all of these alternator part numbers below have been identified as 8215 replacements or equivalent but a few alternators have been found to be different by readers who were kind enough to email me their experiences OEM PN s Manufacturer 8215 AES 8215 LESTER N8215 NEW TECH AL8596X AL8596N AL8657X BOSCH N New X Remanufactured Many databases show different part numbers as equivalent Without investigating each one individually replacement compatibility and ease of i
10. nstallation isn t known for the part numbers shown below in yellow The key identification difference is that an 8215 has a 3 pin electrical connector 186 6134 1866134 BECK ARNLEY 21021310Y 21021447Y 21022772 21022893 21022893Y 21020854 GM 21023515 21023702 21024485 21024726 see red note below 240 5215 2405215 240 5216 2405216 PICTURE ID CATALOG A1842 A1842 LUCAS front and back of the alternator Note I m not able to verify if USALT 1304B is a 105A version of the 8215 alternator Appendix Other Relevant Calculations According to the technical information provided from Bosch the alternator s capable of a minimum of 18 1800RPM and 96Amps 6000RPM at the alternator shaft Thus with an alternator pulley diameter of 2 2 and the engine s alternator drive pulley diameter of 5 14 then a typical cruising engine speed of 2857RPM or greater will allow the alternator to provide 96Amps for recharging the TR7 s battery and supporting the vehicle s electrical loads 6000 2 5 5 25 2857 RPM The Bosch alternator s lowest RPM for providing a regulated output voltage and current is with an alternator shaft speed of 1250 RPM With an alternator pulley diameter of 2 2 and engine alternator drive pulley diameter of 5 14 the alternator can provide output current with an engine speed as low as 595 RPM 1250 2 5 5 25 595 RPM Since the TR7 repair manual indica
11. ration and durability Robert Bosch ID Specification Sheet Page 1 of 1 5 _ Load Test we Y 0 1 Volts Tum On 1250 No Load Set Point 5 14 9 Volts Test Speed 1 1800 RPMS Minimum Output Test Speed 1 18 Test Speed 8 6000 RPM S Minimum Output Test Speed6 96 Special Instructions 10 00 amp Pi 2 D 130 R E 13 5 13 G 12 79 78 W J 78 x K 22 AA L 40 BB M 17 EE 62 http boschservice bv us bosch com cgi bin idspec RunApp aspx 4 8 2008
12. rimped on Red amp Brown wires Mating wiring harness barrel shaped connector is shown on the right Picture 4 Pushing the Bosch 8215 Alternator s mounting insert deeper into its hole Picture 5 Alternator with the pig tail harness installed Picture 6 New Alternator electrically installed ory urdan gt zo 200 Reference TR7 Service Manual page 389 Re Fit 86 10 02 and belt tensioning 86 10 05 procedures 16 17 18 19 20 2l 22 29 24 Install the long bolt through the lower alternator mounts first to support the alternator s weight Install the high current big Brown battery wire in the TR7 to the B stud bolt on the back of the 8215 alternator See also Picture 2 Connect the 85854 pig tail harness s Red wire to the TR7 s small Brown wire via their mating connectors Connect the pig tail harness s Brown wire to the TR7 s small Brown Yellow wire via their mating connectors Install the upper mounting bracket bolt through the bracket and then through the alternator s upper mounting ear Lightly finger tighten Do not completely tighten this bolt Install the alternator belt around the pulley Pull the alternator away from the engine to increase tension on the belt and then completely tightened the upper mounting bracket bolt Then tighten the lower alternator mounting bolt See Picture 6 Re install the charcoal canister and air by pass hoses d
13. tes 850 is lowest idle RPM the minimum alternator shaft speed of 1250 RPM 1s always satisfied At an engine speed of 857RPM the Bosch alternator will be able to generate a minimum of 18Amps 1800 RPM 2 5 5 25 857 RPM If a 2 1 2 alternator pulley is not available 3 6 is the largest alternator pulley diameter that could be used and have the alternator deliver some operating current at engine idle 850 RPM 1250 RPM 5 25 3 6 The Bosch alternator s highest allowed rotational speed is 13000RPM a mechanical limit on the bearing and brushes Again with an alternator pulley diameter of 2 2 and engine s alternator drive pulley diameter of 5 14 the alternator can briefly tolerate an engine speed of 6190 RPM 13000 RPM 5 25 7 2 5 6190 RPM I don t run my engine up to 6100RPM so this limit doesn t matter to me However if you race and operate your engine often in the 5000 RPM to 7000RPM range 2 9 is the smallest acceptable alternator pulley diameter If you use a pulley smaller than 2 9 you ll risk having premature alternator bearing failure 7000 RPM 13000 RPM 5 25 2 9 If your driving habits are like mine general Grand Touring or non racing 2 2 alternator pulley is acceptable for use However if you race and drive at very high RPMs often you ll need to seek out a 2 9 to 3 6 pulley wheel to respect the Bosch alternator s limits of ope
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