Alternator Saga Continues

[Moose]

Last year, I replaced my voltage regulator that was attached to the alternator in my 01 986 5-speed with success-- until today. The bat light came on again and I checked the two top side ground straps of which I know (bat box and passenger side in engine compartment visible from above the engine).

Yesterday, I had NAPA check the battery with the engine off. Good battery. Needs recharge. Then they had me start the car, rev the engine slightly, and turn on the lights with a multimeter-like machine attached to the battery posts.

Their diagnosis is "not enough voltage from alternator"-- however, "no diode ripple detected" from before is not the problem as was the case previously! They suggested I left a plug or wire loose when I reattached the voltage regulator and that the best option was to pull the alternator and have it bench tested to make sure it didn't need to be replaced and then, if not, to shore up the connections and make sure they are tight and also make sure the serp belt is properly tensioned.

Any other thoughts? Will bench test alternator at shop this week. :renntech:

[Loren]

How old is your battery?

[Moose]

How old is your battery?

New last year. Frankly, I've replaced the battery more times than I'd like to admit, but twice it was actually a bad battery-- from Interstate both times. This time it was a NAPA battery and I went back to have them test it (hoping it was merely heat killing the battery within warranty).

I'm dreading putting the alternator back in (regardless of whether it needs to be replaced) because the last two times I've been in there, I've had to remove the coolant plate to which it attaches. Well, the first time I didn't replace the coolant plate gasket and then I had to go back in.

Second query: is there truly anyway to fit the alternator to the block without removing this plate?

87 928S 4 auto "indischrot"

01 986 5 speed "seal grey metallic"

00 BMW 323i black on red

[Moose]

Update: I've had the alternator bench tested and it is fine. The electrician said that it was obvious there was a loose connector at the rear of the alternator/volt regulator because there were signs of it rubbing on the back of the alt and, incidentally, beginning to melt some of the plastic. He took the back off, cleaned the connectors, reassembled it and gave me a second nut to separate the connector from the back of the voltage regulator so as not to melt the plastic and to hold/tighten the bolt into the assembly. He said I should clean the connector that attaches to the alt as it was probably dull or had bits of plastic melted to it and that could affect the system negatively (no pun intended).

It's hard to describe in words, but it made sense and it looks like that was the problem. I will update the list with my findings once reassembled on the car. My question remains, however, if I can put this baby back on the car without removing that coolant plate/bracket to which it attaches and draining the cooling system. Thoughts?

David Cmelik

87 928S 4 auto "indischrot"

01 986 5 speed "seal grey metallic"

00 BMW 323i black on red