Here's a homemade tool for torquing the alternator (Bosch 90 amp) shaft nut. W124 Mercedes DVD repair group 15-5700 calls for 80 Nm to secure pulley to the "compact" alternator shaft. Grind two flats on opposite sides of the 22 mm socket and hold with an adjustable wrench. Insert a XZN 10 mm x 100mm Long Bit 1/2in. drive into the 12 point internal socket of the shaft. My buddy Paul gave me the idea.

I had symptons where most of the dashboard idiot lights turned on while the car was idling. Most were dim except for the battery symbol which was relatively bright and dimmed as engine speed was increased. The ABS light was on at idle and turned off when engine speed exceeded about 1000 rpm.

With the old (bad) alternator I recorded voltage readings across the battery terminals of 12.4v with engine not running, 12.2v at idle, 12.3v at 1500 rpm, 12.6v at 2000 rpm.

With new rebuilt alternator I recorded voltage readings across the battery terminals of 12.9v with engine not running, 14.4v at idle, 14.4v at 1500 rpm, 14.5v at 2000 rpm.

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1995 E300D

Clever idea.
I saved it to my Notes.

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84 300D, 82 Volvo 244Gl Diesel

I had a VW Golf once, and it had the 90A alternator on it, The weird part was that my proxxon tool kit had a spark plug socket with flats milled onto its end like a nut to use a large spanner (wrench) on. It was used exactly the same way you used here.

Pretty weird for the tool to perfectly fit and come out of a general tool kit.

anyway - Look into using a clutch pulley for the alternator - it would reduce the working stress on the belt tensioner and shock absorber.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

Great Idea

1.(But,Where's the Pulley?)
2.(That 22mm don't look skinny enough in the OD dept. to fit inside the ID of
the Pulley???)

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'84 300SD sold
124.128

I imagine the photo was clearer without the pulley on shaft, except for where the heck is the pulley..

Nice idea, snap-on has the thinest wall thickness of a quality socket, which maybe needed.

Great idea, I will be needing soon with 274K on my alternator.

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Gary
Experience is something you get, Just after you needed it....
'99 E300 295K, '83 300D 220K, '75 240D 185K sold
'80 MCI Bus Conv DD 6V92TA, w/4 cyl. Kubota diesel GenSet 12.5KW

Cessna5354 made the right observation - I didn't include the pulley in the photo to better show the tools involved. The 22mm socket fit nicely within the i.d. of the pulley. A standard 22mm Craftsman socket was used.

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1995 E300D

AZ OTC wrench fits perfectly,no filing necessary.
$9.99

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'84 300SD sold
124.128

Cessna5354 made the right observation - I didn't include the pulley in the photo to better show the tools involved. The 22mm socket fit nicely within the i.d. of the pulley. A standard 22mm Craftsman socket was used
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