After driving around a fair bit last weekend found that the "LIGHTS" warning light together with faded battery light appeared on the dash.A search revealed a post of ZCar91's a couple of years ago that this "LIGHTS" warning will occur if one on the fusable resistors in the sensor box at the rear of the car blows . Disconnected the sensor box , no luck. A further search revealed that a blown Engine Control fuse in the relay box located at passenger side front of engine bay can also be the cause (thanks DUB).Found that fuse was blown , however my joy was shortlived two fuses later when upon ignition they would instantly blow.Checked voltage on battery which was about 14.2 volts and appeared normal, under load lights/aircon etc decrease was also normal. This temporarily ruled out my initial suspect which was the alternator.Did a bit more research including Chili's post on his voltage regulator problem.Formed an opinion that the cause of the fuse blowing instantly could be as a result of voltage spikes due to a faulty regulator which is enclosed in the alternator.Fitted a replacement alternator which is a bit fiddly but not an overly difficult job. Tech located in Auto-FAQ on TTnet is a good guide.However, the main 17mm bolt which threads through the top of the alternator connects to a nut which is welded to a base plate and in turn needs to be held in place at the rear of alternator while bolt is pushed through prior to tapping.Unless you have hands the size of a midget this seemed to me to a very difficult task. Decided to put a bit of Superglue on the base plate/nut and had in perfect position prior to reinstalling the alternator. Not too scientific but worked well for me.Started car, everything was fine. Too my relief the voltage regulator was causing the problem.Once again infomation found on "Search" on this forum was a great help.Tony
I put in a new alternator last week mine had been charging at 18.5V! Blew both raybrig headlight globes and caused acid to spill out of the battery. I acually think it is one area of the zed that isnt very well designed, if the regulator goes it seems to overcharge in most cases. Quite a few people on twinturbo.net have had their battery explode from overcharging, im now thinking a dash mounted volt meter might be a good idea.
