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Fire in engine compartment, now need info on alternator wiring .... 200 1993

Hi all. I need some information on the wiring in the area behind the alternator on a '93 240.

The background story will better clarify the kind of information I need. I'll start by describing what happened. I had taken my wife's car for a MacDonalds run last night, about 3 minutes away from our house, and on the way back I gradually started smelling an acrid odor (roasting electrical insulation) and as I slowed for the turn into my driveway both the alternator and oil pressure lights went on simultaneously, so as soon as stopped in the driveway (instead of inside the garage, afraid of burning down our house) I jumped out as I popped the hood (and btw those indicator lights stayed on even after the key was removed) and I saw in the darkness a bright but small (~1 inch high) orange flame directly below the oil pressure sender (right on top of the subframe cross-member). I ran into the house, got a small bucket of water and (as I ran out through the garage) grabbed a wrench from my workbench, drenched the area of the flame and quickly loosened and removed the negative battery terminal.

Now, in the daylight hours I can see that the wires in the area between the alternator and oil filter are charred -- not sure which and how many yet, but I surmise that some wire(s) either crossed or grounded through worn insulation and caused the short-circuit. I plan to slit open the black sheath over the wire bundle (that extends from behind the engine forward toward the alternator) and find where good wire still remains, hoping they aren't melted all along their length, and from there crimp* on new wire and lead them to the alternator and oil pressure sender.
[ * I have marine crimps of various sizes, shrink-wrapped (and adhesive lined) for a good seal, and a good crimper. And various gauges of good marine-grade wire.]

But here's my problem. I've never really looked at the back of the alternator to know how the wires are laid out and attached -- I've even changed the mount's bushings once, while leaving the alternator largely in place and without even glancing at the wires, so it's new to me. Although I have the 1993 Wiring Diagram (Volvo) green book, it just has line drawings of the wiring. My only green book of the Charging System is for my 1984, and even that's not too helpful, nor is my Bentley.
All in all, I interpret from those diagrams that there "should" be merely four wires (including the oil pressure sender wire): 1 red from the starter and battery; 1 red to the idiot light and beyond; 1 ground wire (color black?) from the alternator; and a wire (color black?) to the oil sender. And are there any other wires (capacitor's wires)? A line-drawing diagram isn't the same as a real view. So I ask these questions with which you guys can help, noting that I'd prefer to know these before I pull out the alternator so I don't screw up the wires' identities in case some fragile (from the heat) wires snap off and gets confused:

1) Am I right about the total number of wires? There's also a suggestion in the diagrams that there's an additional set of external wires for a capacitor on the outside(?) of the alternator's case?
2) I need to know how each of these wires are connected to the back of the alternator (which one attaches where?); and, referring particularly to that black block I see, whether the wires come off with it or it stays on the alternator and the wires come off of it. If that block is supposed to come off, how is it released? If so, is it obvious/intuitive or is there a "trick" to it.
3) An actual photo of the back of the alternator, with all of the wires attached, would be most helpful for the preceding (2).
4) My Wiring Diagram book, in the beginning pages ("Ground Connections") inexplicably fails to include a sketch of how and where the alternator's ground wire is connected to the chassis. And there's no indication of that ground wire's color (unless it's a standard "black").
5) Is there any other wiring bundle in that area (possibly from the front of the engine), besides the black sheath along the lower right side of the engine compartment?

All in all, I expect (worst case) to be doing a complete rewiring in that area with little knowledge of how it was or should be (and being charred, no info on color coding), as well as how they're connected, so any specific information about where and what to hook up will be invaluable.

Much thanks to all of you.
Ken






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New 1 Fire in engine compartment, now need info on alternator wiring .... [200][1993]
posted by  Ken C subscriber  on Mon Feb 6 10:43 CST 2012 >


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