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One of those dreaded alternator failure, replacement, still something wrong issue solved!

413 Views 13 Replies 3 Participants Last post by  2ndGenMaintainer
Hi Family!

Recently had the alternator brake and battery light issue. In this case, I had a bad voltage regulator harness found while removing alternator. Soldered and shrunk a new harness on improperly. Had same issue as before new alternator.

Key issue: charging system tester reading "charging high". Limp mode after driving a few minutes, but brake and battery light are off.

Solved in this particular case by correctly wiring new alternator voltage regulator harness.

For some reason I can't get into the nicoclub manual to verify wire color coordination. However, this link is to a video where this very kind gentlemen layed it out very easily.


The harness being melted before the alternator was replaced, was most likely causing the limp mode symptom. Still yet, after I replaced the alternator, I mis-wired the harness and it still had the same symptoms. The old alternator may have very well been fine in this case with a bad regulator most likely. Unfortunately, I won't know the answer to that question.

107k first replacement of alternator!!

100% honesty : failed to securely tighten battery post terminals. My negative bolt rusted/rotted and I thought I was tightening it while it was actually just spinning. I didn't catch it till now. My fault I think. Probably caused heat at the alternator voltage regulator harness connections. I did notice some corrosion on the battery terminals at time of service lol.
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I think the melted alternator plug/harness thing is kinda common (seen a few videos of people repairing these) so I'm not sure your loose cable clamp was necessarily the root cause. I suspect I had a plug/harness problem in my 2nd gen too that intermittently caused a no-charging condition until I disabled the vvcs function that is controlled and sensed at that plug. But it's so tight to work in there I'm putting it off replacing the plug. I bought the replacement plug but am just dreading doing it. Did you drain the coolant and remove the top radiator hose and fans to do that plug splice job? And do it from the top or the side? Take any photos of your job? Would make a good DIY.

The FSM recommends to disable the vvsc as the first step in any no-charge troubleshooting by disconnecting the battery current sensor. This will tell you if your regulator is still good or not by disabling the external controls that could make it appear like your alternator isn't working. I couldn't get mine unplugged but that's how the FSM recommends to start troubleshooting to avoid misdiagnosing the alternator as bad. That looks like alot of tight and tricky work to DIY the alternator swap only to have the same problem after.....

You might try another browser if you can't get the nicoclub site to work. I can't get the manuals to work in Chrome but Edge(!?) works for me. Might just be some browser settings I've made in Chrome and never made in Edge because I never use it. Those manuals are key to figuring so much stuff out.
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2ndGen, strange timing but I saw a Nissan Maxima dies while driving video today that sounds even more like your original failing alternator situation. Don't know if you've ever seen Eric O. on South Main Auto channel on youtube but he does a bunch of good diagnosis videos and this one happens to be on our exact charging system. In this video he gets a Maixma that goes into some kind of limp mode due to high charging voltage rather than the battery dying from low voltage. This one would flash the battery light sometimes. He ends up replacing the alternator and not the harness even though the Nissan dealership quoted $2000 to replace the harness. They must have been thinking it needed that plug/harness replaced too.

He cleaned up the battery connections in this one too because they looked crappy so maybe the loose battery connections had something to do with the original cause of the alternator failure after all.

Check out this video and tell me that doesn't sound like your car's behavior..... there's a part 2 where he completes the repair.
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Sky, sounds like all 3 of us need new alternators. Good job getting that out and back in so quickly. That looks like a tough job. Did you take it out the front or the side? Did you disconnect AC lines? Or drain coolant/move radiator? I'm trying to decide how to tackle this.
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