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  #1  
Old 10-19-2009, 11:39 AM
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Did I install my alternator correctly?

This is for my 1982 240D

Alternator was not putting out full charge and the alternator fan was sometimes hitting the alternator, making clanging sounds. Decided I needed to replace it.

When I pulled the pulley off, from the order of alternator to the nut, I had alternator, fan, spacer, another spacer, pully side, other pully side, spacer, lock washer, then nut.

When at the parts store, two issues. The guy there said first off the spacer was in the wrong order, as well as the woodruff key would not fit the new alternator, but that is ok because it is not needed.

New alternator is installed and working fine, but just wanted to make sure I will not run into problems - wanted to confirm a couple of things:


1. The parts store guy had the alternator, then spacer, fan, another spacer, pulley side, other pully side, spacer, lock washer, then nut. Is this way correct or should it go the way the old alternator came off?

2. Is it true I can just leave off the woodruff key and not have any trouble?

3. The alternator does get hot - but have not touched a lot of alternators, so dont know if this is normal lol.

4. Not sure how tight the belt should be - right now I can push down about 1/2 inch flex between pulleys - does that sound about right?

Thanks all, I think i should be fine but just wanted to check with the experts.

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Old 10-19-2009, 01:59 PM
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The question of a spacer between the alt body and fan can be answered by clearence between the two, and belt alignment. The rest sounds good. My question is, "Unless the shaft is tapered, what keeps the fan from slipping on the shaft w/o the woodruff key?"
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Old 10-19-2009, 02:41 PM
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This is from the epc.
Attached Thumbnails
Did I install my alternator correctly?-alt-240.jpg  
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Old 10-19-2009, 02:48 PM
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I concur a key is required. When alternator goes to full charge it draws quite a bit of mechanical power. I have to wonder why the key did not swap over?

Also measure your battery voltage with the engine running. If this test is not conclusive have the battery tested at a free place. A marginal battery could be making the alternator overcharge too much or requiring a constant heavier duty cycle than normal.

Many alternators are finished off by bad batteries. I also find it strange a counter parts guy would know the sequence of washers etc. Yet not know the key is required. The pulley was never designed to stay in place by surface friction alone.
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Old 10-19-2009, 03:50 PM
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Thanks for the replies, and the pic from the "EPC". The picture does not show any of the spacers which is strange.

As far as the woodruff key is concerned - when at the parts store they had several re manufactured alternators, different brands. None fit the woodruff key. The key was too big for every single alternator we tried, which is why I installed without it.

It is charging the battery correctly, but you think this may cause trouble in the future?

Thanks.
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Old 10-19-2009, 05:56 PM
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IIRC, my reman unit, a Bosch, I think, needed to use my old pulley and the woodruff key did not fit, but the place had one that did. The epc was for your year and engine, 1982 240D.
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Old 10-19-2009, 06:02 PM
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You need the woodruff key, it is there to keep the pulley and fan from slipping on the shaft under full load.

You should be able to buy a key from any good parts house or even a local hardware store usually has a good assortment, probably less then $1.
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Old 10-19-2009, 06:11 PM
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Just to confirm, are you saying the woodruff key fits the fan but not the shaft? This isn't unusual, but a decent parts store should have woodruff keys of varying thickness available. If all else fails you can file it down but it's kind of tricky with such a small piece. I agree with others that you should have the key installed or you may become stranded it the pulley parts company from the front of the alternator. A replacement pulley might be even more difficult to come by.
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  #9  
Old 10-19-2009, 10:37 PM
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You can purchase stepped woodruff keys from a good industrial supply house. The only problem would be, it is probably a metric sized key. As previously suggested a new key and a steady hand on a good file, it is possible to make a good homemade stepped key. Good luck.

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