Let me start by saying that this website is loaded with everything for the "do it for yourself" mechanics. The members provide support and the tricks of the trade for everyone.

I bought my 240D about four months ago and it ran great until a few weeks ago. The instrementd ash gage lights came on (Brake, Break Pad Sensor, Battery) and wouldn't go off. At that time I started investagating to see if any other members had the problem. I found that it might be the alternator. I called a buddy of mine at the local parts store and he sold me a rebuilt one at his discounted price. The alternator was a 55 amp. I proceeded to install the alternator, and it cured the dash light problem and the car ran great.

Two to three days later my wife stated that she was driving home and the lghts were really dim, and the heater wasn't blowing. My first thoughts were the blower motor fuse. I removed the access panel and saw that the fuse was blow and the metal connection was damaged. I put a by-pass fuse link in and the fan came back to life. I then proceed to recharge the battery and it tested fine 12.4 volts sitting. Becuase the alternator was under warrenty my buddy exchange it and upgraded it to a 65 amp one. I put it in for her and the car ran great again.

The same problem is occuring again. The light are really dim and the heater fan stopped working after a few minutes. I got out my multimeter and was testing the battery while sitting idle and while on a load. I noticed that the battery at idle went from 12.4 (engine off) to an average of 13.4 volts. When I put a load on the alternator for instance the lights the battery started to lose its voltage slowly. When I turned the heater fan blower on the multimenter readings dropped faster. I then turned off the blower and the light and let the alternator recharge the battery.

I the volts came back up to around 13.4 on the battery and then I disconneted the battery terminals to see what would hapen. As I thought the alternator couldn't keep up with a load put onto it. I stopped a few minutes into the test. I have verified all gound connections are clean and even replaced the ground cables becuase I noticed some corrosion on them. I also cleaned the battery terminals.

I read that the glow plug realy might be putting a amp draw on the system and I preformed that test by disconnectig the plug while the engine was at ide. Cheched my multimeter and there was no voltage change. I also verified that the voltage regulator and brushed attached to it were in good shape. The brushes appear to be new with no excessive wear.

Is there anything else that I am missing or not testing? Or did I get another faulty alternator. My 240D doesn't have any upgrade options on it.

I don't want to give up on the car. The car has been great but it has been cold up here in the north and the heater is needed badly. Any insight on this problem would be appreciated.

Thanks in advance.

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Current:
2005 Dodge 2500
1999 Chevy Venture

Previous:
1977 240D
1977 300D
1982 240D
1982 300 TD
1984 300 TD
1990 190E