I noticed the battery light come on?

Tiny
CHRISTOPHER SA
  • MEMBER
  • 1993 BMW 320I
  • 2.0L
  • 6 CYL
  • 2WD
  • MANUAL
  • 130,000 MILES
Yesterday, I took off one of the leads from the battery to change the airbag module behind the glove box to put back the original module as the one I purchased off of eBay didn't work. After getting everything done, I reattached the battery cable (the red one).

Today while going somewhere, I noticed the battery light come on for the first time since I have had the car (2015). I got to where I was going, which was about 3 miles. I parked and spent around two hours at the location I went to.

When I got back in the car the engine turnover was sluggish as though there was not enough juice to the starter motor, though the engine did start. A friend who was leaving the same location later told me that the lights were dim.

I got to another location (my friend's house) ok, which was about a mile away. The battery light dimmed when the car got up to speed but became brighter when stopped at a light.

I didn't notice anything untoward at this point.

When leaving my friend's house, the start of the car was again sluggish. When getting to the first light near my friend's house I noticed that the engine was losing power so I revved the engine and found that it had picked up power. I had to keep the engine at high revs so that the engine would not stall.

I had to zoom off the line when the lights turned green otherwise the engine would bog down.

There were two more sets of light, and I noticed that if the engine went down to idle (800RPM) the engine would lose all power, so I let the car roll forward and let out the clutch to restart it that way. I then tried keeping the revs high and tried to continue on, but I got another few hundred yards down the road when all power died.

The weather has got cold, but I suspect that either the red lead to the battery was not put on properly, the alternator has gone, or the battery lost charge due to the weather.

The car does have an integrated alarm (a BMW one) with a blinking red light.

In the past I have noticed the blinking red light does drain the battery over time if the car is not used.

But there have been no issues with the battery being drained as the car has been used nearly every day.

Is there a way to determine what has happened without taking the alternator off and getting it tested?
I actually went back to where the car was left, the same night, took the battery out and got it home and charged it overnight. I went to the car this morning, installed the battery, after it had been charged to around 15V (it had 11.9V when I started charging it), and the car started right up but the battery light still showed.

I got home okay, about a mile away, and then took the alternator out and sent it off to be tested and, if necessary, refurbished.

I had the alternator looked at and it is toast! The rotors have completely worn out, so it was the alternator that caused the issue. A new one is being ordered.

Thanks in advance for the help.
Tuesday, November 26th, 2024 AT 7:22 PM

21 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
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Nice work, here is the correct way to install the alternator. Check out the images (below). Let us know if you need anything else.
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Wednesday, November 27th, 2024 AT 4:48 PM
Tiny
CHRISTOPHER SA
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Thanks for the info, Ken.

I had a comedy moment when taking off the alternator. I got the top bolt undone then went to do the bottom bolt which ended up taking about 30 minutes or so. I was wondering why it was taking so long and when moving the alternator to one side (pivoting on the bottom bolt) I saw that there was a nut on the other end! Once that was seen I got a socket to it to prevent it from turning and had it out within a few minutes.

Oh well. One lives and learns!
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Wednesday, November 27th, 2024 AT 5:03 PM
Tiny
KEN L
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Yep, we all learn together. Glad you could get it fixed, thanks for letting us know. Please use 2CarPros anytime we are here to help.
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Thursday, November 28th, 2024 AT 11:40 AM
Tiny
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Just to finish up I have installed the new alternator, and everything works as it should/ The increase in alternator power has not caused any issues with the wiring. Here are a bunch of pics to show the difference between the 80A and the 140A:
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Sunday, December 1st, 2024 AT 12:38 AM
Tiny
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Another pic.
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Sunday, December 1st, 2024 AT 12:38 AM
Tiny
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And another.
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Sunday, December 1st, 2024 AT 12:39 AM
Tiny
CHRISTOPHER SA
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Another.
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Sunday, December 1st, 2024 AT 12:40 AM
Tiny
CHRISTOPHER SA
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Another (there is an issue with adding or deleting images, when deleting the option to add images disappears. When adding one cannot delete an image when uploaded in error hence why there are two in some posts).
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Sunday, December 1st, 2024 AT 12:40 AM
Tiny
CHRISTOPHER SA
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There are some images of the alternator in situ.
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Sunday, December 1st, 2024 AT 12:47 AM
Tiny
CHRISTOPHER SA
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Two of three
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Sunday, December 1st, 2024 AT 12:48 AM
Tiny
CHRISTOPHER SA
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3 of 3
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Sunday, December 1st, 2024 AT 12:49 AM
Tiny
CHRISTOPHER SA
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The old pulley can't be used with the new alternator and here is the new pulley.
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Sunday, December 1st, 2024 AT 12:50 AM
Tiny
CHRISTOPHER SA
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Even though the new alternator is larger than than the old one it just slots into place without any adjustments to anything.

A note about tightening the nut. The nut is 24mm and the hole in the axle of the alternator needs a 12 spline T50 torx (or an M10)/star bit.

I used a shallow 1/2 inch 24mm socket, wrapped the socket end in electrical tape about ten times, gripped it with mole grips then put the T50 torx bit through the socket hole into the axle splined hole and turned this bit anti clockwise with a 10mm spanner to tighten the nut to the axle to hold the pulley firmly in place.
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Sunday, December 1st, 2024 AT 12:52 AM
Tiny
KEN L
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Thanks for the info, it looks like the problem is solved? Nice work installing the higher output alternator.
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Sunday, December 1st, 2024 AT 10:34 AM
Tiny
CHRISTOPHER SA
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Hi Ken,
Yes, the problem has been resolved. Thanks for the help.
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Sunday, December 1st, 2024 AT 11:41 AM
Tiny
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Oh, and one more thing, I had to also buy a new battery as the old one was no longer charging. It had been in the car for 10 years though!
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Monday, March 31st, 2025 AT 2:38 AM
Tiny
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There is just one item that is puzzling me.

The bolt that attaches the bottom of the alternator to the block is sticking out by about 0.75 inches - which means that I was not able to tighten it so that it was flush against the metal of the alternator. I found that mighty puzzling as these bolts are really long and the top and bottom bolt are different lengths with the bottom one being the longest. I had also placed the bolts in different places so that I wouldn't get them mixed up. From the pictures the alternators seem to have the same dimensions so I am left with a very weird result and not sure if its okay to leave a bolt sticking out so much. At the back of the alternator the bottom bolt comes through by about 0.75 inches beyond the nut attached to the back of the alternator bracket, so its really confusing me how this has happened. With the old alternator the bolt would protrude beyond the nut by about a 1/16 of an inch!

There is now a slight screeching coming from the belt (which is only a couple of thousand miles old or so) but goes away after the engine warms up, and am wondering if that has anything to do with the bottom of the alternator not being tight to the engine block (since the bolt is sticking out the 0.75 inches).
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Monday, March 31st, 2025 AT 2:47 AM
Tiny
KEN L
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Yes, that is not good, can you upload an image of the bolt in question?
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Monday, March 31st, 2025 AT 12:07 PM
Tiny
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Yes, I'll do this probably on Thursday when its warmed up here.
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Monday, March 31st, 2025 AT 12:48 PM
Tiny
CHRISTOPHER SA
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Here are some pictures showing what is going on. After these pictures were taken, I was only able to tighten the bolt so that it went half the distance that is showing it being proud of the alternator. I was worried about breaking the bolt, even though I was still able to turn the bolt, albeit with more force than normal. I have also shown the top bolt to show you that it was correct in size.

I was not able to get a picture of the back of the alternator as there was not enough room to get the camera down there. I was able to feel the protrusion of the bolt and it was about 0.5-0.75 inches coming out beyond the nut on the back of the alternator for this bolt which is a lot more than before. Very puzzling.
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Thursday, April 3rd, 2025 AT 8:11 PM

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