EMBPilot

nothing was loose.
i cant just put it back together cause the pulley wont go back on the shaft in its current state.

Confirmed w shop the reman unit is a Bosch.

Have not done anything to the shaft except emery it enough to get the pulley off.

Quadcammer

have you wire brushed the shaft?

EMBPilot

ive been in touch with the shop owner who swapped the alternator. hes been very responsive and helpful. without giving him any details, just the symptoms, his hunch was the belt was too tight.

he recommended i bring this unit back to him, and he'll exchange it under warranty. i dont think thats a bad idea. time crunch is now off since the car is sitting in my garage... given we are the ones who installed the belt wrong (if thats what this is...) i felt like it was kind of him to offer that at no cost to me.

Edit:
Dropped off alternator.
New alternator will be in tonight.
Ill shoot for a reinstall w more shims Friday night after work or this weekend.

There was a single .5 I think on there now, I guess I'll see how it looks w a .5 + .7

SkiDan

Sorry to hear about your ordeal. Subscribed in anticipation of reading about a successful resolution to the problem. Good luck!

EMBPilot

a few questions... and comments.
got the new alternator today. this one looks much better than the last.

Ordered new alternator pulley halves should be here mid week, just in case my current ones got messed up during all this...

i can replicate similar sounding fan scraping noise if the nuts on the rear cone are not tightened carefully. I got 4xM6x1.0 nuts to run down the rear studs to seat the alternator back tightly. i'll remove them before putting on the rear cone. but at least i know the alternator is fully seated, and the fan spins freely without any scraping.

Quadcammer

holy crap that looks way better

EMBPilot

anyone happen to know the specs for the bolt that holds in the ground lead on the back of the alternator?

the one I have in front of me does not have it installed like the last one.

Edit: it's M5 thread x 10mm but i can't measure the pitch. And it's not .8 or 1.0

Edit 2: alternator is in. Got the bolt. Waiting on parts. Will update.

Dudley

Although I think the alternator pully is a likely source of the noise, is there anyway the fan housing could be misaligned with the top of the motor? If the housing is not centered on the key on top of the motor, the fan housing will not settle properly. When you tighten the securing strap, you could force the housing slightly out of round.

AOW162435

While anything with a rebuilt alternator is possible (bad alternator bearings, etc.), I still think your last alternator was not fully seated in the fan housing. The last alternator housing may have been damaged in some way, preventing it from seating / keying correctly.

Let's hope this one does the trick.


Andreas

XavierLaFlamme

This is a good point. It took me a bit of wrangling to get the shroud seated properly on top of the engine.

There is so little clearance between the fan blade tips and the shroud that getting the alternator torqued down properly is so important.

I hope everything works out. I am sure it will!

--Michael

EMBPilot

Thanks guys, im waiting on new alternator pulley halves, fan pulley bolts, and alternator belt.
I have KR1 so i'll do the tensioning routine to check tension as well.

im going to start with a .5 and .7 shim on the alternator and go from there. possibly add one additional to the fan.

the fan shroud strapis torqued to 8nm, and is seated on its pin. i made sure the alternator was pulled back into its housing (re: earlier post).

the last of my parts should be here Wednesday, and i'll report back when i tackle it Thursday.

edit. post script...
if the rear stud nuts are tightened one at a time, or unevenly, i was surprised to see how little it took to make the fan scrape or jam completely just checking it with my finger while 'pulling it back'...

EMBPilot

thanks gents for all the help and support here. esp Andreas, Alex and Quad.
finally got around to attending to p-car... good outcome

i believe this was a result of the belts simply being way too tight.
using the Porsche Workshop manual and the KR1 i was able to get the belts to spec. i added an additional shim to the fan belt ( i think there are 3 or 4 on there). The new alternator belt was last installed using a single .5mm shim. after following the thumb test and KR1, i got it within spec using three .5mm's and a .7mm and its right between where it should be. after test driving it was at 20kg with the low limit being 18. i'll recheck this stuff after a few hundred miles. was awesome to get the car out again, i really missed driving it.

AOW162435

Kevin,
That's great news. Congrats for pushing through and getting it handled.


Andreas

mjsporsche

'nuff said.

Mark

Quadcammer

lets go drive suckers.