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'Brought home to do myself (alternator)'...I've got problems, may need help.
Ugh,
If you've followed my thread about bringing my car home from the shop to remove, rebuild and re-install my alternator only to discover at the alternator shop that the mechanic was wrong...my alternator is fine, it was the regulator, then that's the short story. Now...got off work and to the car with the parts I need to put back: alt., reg. and new belts, etc. I ave up at 10 pm and came home a bit dejected. Problem is after getting the alternator wired back up, air diverter put back on (PIA) and got the shroud/fan assembly back in...the fan is rubbing. What a ***** it was to get back out using a modified 'puller' (I didn't want to have to unhook all those wires/loosen and remove screws, etc. if I didn't have to...good thing I have a magnetic nut and washer finder  )Don't know if the alternator isn't seated perfectly in the housing...or need to tighten the bolts again...or a problem with the 'key' in the alternator shaft? I've got to go at it again tomorrow and get this car out of my friend's garage...help!  Ryan
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To the memory of Warren Hall (Early S Man), 1950 - 2008 www.friendsofwarren.com 1990 964 C4 Cabriolet (current) 1974 911 2.7 Coupe w/sunroof 9114102267 (sold) 1974 914 2.0 (sold) |
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10-24-2002, 07:42 PM
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do you have a stack of the shims handy?
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Remember our friends: Warren, Ron, Grady, and Steve. 76 912E RS (i.e. "Real Slow"); 63 Volvo P1800 "S"; 71 Jaguar XJ6 Series 1; 05 GT3; 23 Cayman GTS 4.0; 97 Boxster |
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10-24-2002, 07:44 PM
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Dave,
It isn't the shims...I have plenty. The fan isn't seating properly. It doesn't look 'obvious', but it is crooked. It's rubbing the housing on one side. I painted the fan and housing so it's easy to tell where... Ryan
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To the memory of Warren Hall (Early S Man), 1950 - 2008 www.friendsofwarren.com 1990 964 C4 Cabriolet (current) 1974 911 2.7 Coupe w/sunroof 9114102267 (sold) 1974 914 2.0 (sold) |
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10-24-2002, 07:54 PM
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Well,
Just waiting on my girlfriend to pick me up and drop me off at the garage. Guess I'll be taking off half a day to get this done, hopefully. Sure wish I knew why the fan is rubbing...still guess that the alternator must not be seated right. Think I'll pull it all out and start over.   Ryan
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To the memory of Warren Hall (Early S Man), 1950 - 2008 www.friendsofwarren.com 1990 964 C4 Cabriolet (current) 1974 911 2.7 Coupe w/sunroof 9114102267 (sold) 1974 914 2.0 (sold) |
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10-25-2002, 03:52 AM
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I recently had a similar problem. I tightened all of the nuts on the back on the bench to make sure it was seated and then backed them off to put the air director on, that helped, but it still rubbed a little. When I put it all back to gether and torqued the pulley bolt I forgot about the rubbing..... Started the car and it was fine??? Try using an impact on the pulley bolt (not to hard) to really seat that fan.
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10-25-2002, 04:02 AM
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Elombard,
Yeah, it's strange alright. I've tried tightening down the bolt as hard as I can (didn't try impact wrench), but it still didn't seat. As much as I hate it, I'm going to pull it all out in a few minutes and try seating on the bench again (make sure I can) and then re-install. Don't know what else to do, really. This is the kind of thing that turns fun into stress...  Ryan
__________________
To the memory of Warren Hall (Early S Man), 1950 - 2008 www.friendsofwarren.com 1990 964 C4 Cabriolet (current) 1974 911 2.7 Coupe w/sunroof 9114102267 (sold) 1974 914 2.0 (sold) |
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10-25-2002, 04:10 AM
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Location: Los Alamos, NM, USA
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Ensure you have the alternator firmly and squarely seated against the fan shroud (the piece with fixed vanes that is held to the engine with the metal band). Ensure that the hub extension on the back of the alternator is properly seated and in the correct orientation; usually if the hub extension is rotated the vanes will hit and one can't even get the alternator under the engine shroud (colored fiberglass piece). Make sure you have the little wave washers and nuts properly tightened. This is difficult as you're working around the fan shroud and the alternator's forward movement is limited by the wiring harness passing through the center hole in the hub extension. Don't forget to attach the braided ground strap from the alternator frame to the top of the engine. Then ensure the fan shroud evenly and squarely seats (there's a pinning feature at the bottom of the shroud) on the top of the engine. Tighten the fan shroud clamping band but do not overtighten as one can distort and/or crack the fan shroud (a cause of fan rubbing). Then there is a washer that slips against the alternator on the alternator shaft; if it is stepped (two diameters) the smaller diameter goes towards the alternator. Next there is the half moon shaped key, curved edge into slot on alternator shaft. Then put on fan and ensure it is properly seated; get the key way properly oriented. Follow with some of the alternator shims; I suggest you start with three. Slip on belt followed by outer pulley half and balance of alternator shims. Next the concave or dished washer; concave side towards the outer pulley half. Put on alternator shaft nut and tighten using proper tool (came with car tool kit) to hold fan/outer pulley. Make sure every thing stays seated and in place (especially the alternator shims) during this operation as the belt tension tends to pull to one side and cause a wobble if one isn't careful. Cheers, Jim
Last edited by Jim Sims; 10-25-2002 at 05:18 AM.. |
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10-25-2002, 04:23 AM
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Bigchillcar,
It's a lot convenient to remove the whole assembly and perform your alignment on the bench top. The first major problem I had was removing the fan from the alternator shaft. I suggest that you improve the removal of the fan from the alternator shaft. Emory cloth will help. Take time to jot down the connections before disconnecting the wire. After a few removal, you'll memorize the wiring. Would you consider up grading your alternator with the new alternator with built-in voltage regulator? My '78SC was having problems with the old alternator (20+ years old) and I'm satisfied with the replacement. Have fun....... BoyT911SC |
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10-25-2002, 04:28 AM
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The other thing and Jim has mentioned this is the band around the fan shroud. Make sure it is not to tight ... this can cause rubbing
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10-25-2002, 04:33 AM
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Ditto on tightening the belt. I think I know someone who actually caused a stress fracture on his fan housing some years ago......made a terrible noise.
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Fred '95 Carrera2. Previous: '69S, '79SC, '84Carrera, '90 C2, 20+ years and counting...... |
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10-25-2002, 05:50 AM
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Yeah, I think that big bad hex bolt that tightens the metal strap has a torque spec of something like six lb/ft. That's not much more than finger tight.
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Man of Carbon Fiber (stronger than steel) Mocha 1978 911SC. "Coco" |
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10-25-2002, 08:32 AM
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VICTORY!!!
 Okay, so it took from 7:30 this morning until 11:00 am to take apart again, ensure the alternator was seated properly in the shroud (tha major dilemma last night) and assemble everything together on the bench before re-installing...just like you were saying, Jim. I finally decided that a rubber mallet was needed to go around tapping the altenator to ensure a good seat in the shroud...anything short of that produced rubbing with the fan. Boy what a feeling it was to get that worked out! That alone was almost 2 hours of head-scratching. The new voltage regulator (Bosch) has a slightly longer housing than the previous Bosch and I wasn't able to take the time to get a good mount, but it isn't going anywhere the way I have it. That will be the next 'little' project! Anything noticeable? You bet. The alternator light used to take 2500 rpm's to go out...now it takes 1500 approximately. Boy did I ever learn a lot doing this myself (alone without guidance this am!) I can honestly say my mechanical confidence with this car just took a gigantic leap and I wouldn't back away from doing this again. Curious though, the book I had didn't mention nor show pics of the air-diverter. Do some people remove these from their cars I wonder? Thanks again for all the great help, guys!  Oh yeah...here's a beer first one to reply gets it! 
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To the memory of Warren Hall (Early S Man), 1950 - 2008 www.friendsofwarren.com 1990 964 C4 Cabriolet (current) 1974 911 2.7 Coupe w/sunroof 9114102267 (sold) 1974 914 2.0 (sold) |
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10-25-2002, 09:00 AM
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congrats!!!.. I know the feelin.. I'm just starting the work on my porsche but that feelings a great one.
BTW I take payment in guiness how do you get the beer icon?
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Tim 1973 911T 2005 VW GTI "Dave, hit the brakes, but don't look like your htting the brakes...what? I DON'T KNOW, BRAKE CASUAL!!!" dtw's thoughts after nearly rear ending a SHP officer |
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10-25-2002, 09:03 AM
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Do not remove the hub extension (diverter) as the vanes mounted on it ensure proper air flow to the driver's side of the engine. Jim
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10-25-2002, 09:13 AM
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"BTW I take payment in guiness
how do you get the beer icon?" (how do ya'll show those bold quotes?!) I have 'top men' working on resolving that problem...! In the meantime, here's a six-pack to get you started! Ryan
__________________
To the memory of Warren Hall (Early S Man), 1950 - 2008 www.friendsofwarren.com 1990 964 C4 Cabriolet (current) 1974 911 2.7 Coupe w/sunroof 9114102267 (sold) 1974 914 2.0 (sold) |
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10-25-2002, 09:18 AM
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LOL nevermind.. if I wasn't so blind I'd actually see the "more smiles" button"
1 down 5 to go 
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Tim 1973 911T 2005 VW GTI "Dave, hit the brakes, but don't look like your htting the brakes...what? I DON'T KNOW, BRAKE CASUAL!!!" dtw's thoughts after nearly rear ending a SHP officer |
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10-25-2002, 09:20 AM
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Jim,
Yeah I could clearly see it's purpose, but just wondered if some feel that it's contribution to cooling isn't substantial? Ryan
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To the memory of Warren Hall (Early S Man), 1950 - 2008 www.friendsofwarren.com 1990 964 C4 Cabriolet (current) 1974 911 2.7 Coupe w/sunroof 9114102267 (sold) 1974 914 2.0 (sold) |
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10-25-2002, 09:20 AM
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Quote:
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Ronin LB '77 911s 2.7 PMO E 8.5 SSI Monty MSD JPI w x6 |
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10-25-2002, 09:48 AM
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 Guess that sorta look like Guiness! Ryan
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To the memory of Warren Hall (Early S Man), 1950 - 2008 www.friendsofwarren.com 1990 964 C4 Cabriolet (current) 1974 911 2.7 Coupe w/sunroof 9114102267 (sold) 1974 914 2.0 (sold) |
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10-25-2002, 01:29 PM
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1974 Porsche 911 2.7
1973 Porsche 911 2.4 MFI
