Ha ha ha Phil!

I avoid them electric cars like the plague! Not for their alternators which may be expensive to replace, but for their expensive battery, fragile transmission and light body! They can't have tough heavy body like Volvo for energy saving purposes! And talk about crash safety??


To OP:

I've just reading thru this thread but couldn't help but notice like Phil said, its just an alternator!

An alternator consists of its two body halves, two bearings, snubber capacitor, diode assembly, voltage regulator assembly, coil windings at armature and stator. They are NOT complicated. There are many videos at youtube showing how to replace/service these. For me its DIY. During this writing I'm waiting for the shipment of new SKF bearings for my old alternator.

And I'm a medical doctor nothing of engineering background. But hey...I can still read them technical papers! Anyhow knowing technical knowledge may help in troubleshooting BUT we're still stuck with same designs. We still order same new parts to replace same old parts. Technical knowledge may help but you can't change the design (this needs someone with PhD in engineering). So back to simpler life!

Your symptoms of dash light not turning off looks like there is no voltage output from the D+ post. This may be due to defective diodes in the diode assembly (other than faulty ground wires - hope you've checked those). These D+ diodes are usually smaller in size than the main diodes thus they may be easily damaged in use. Replacing the entire diode assembly would do. Cost? Should be around $30 to $60 depends on alternator amperage/part quality.

Here's one website:
http://store.alternatorparts.com/bosch-3.aspx

Regards,
Amir.