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cchan · Post by **cchan** » Sat Jun 06, 2009 10:24 am

Hello,

Well I went to the Simon's shop and we checked the alternator. It is not charging and therefore we need to get a new one. Just spoke with Phil and went over my options and we wanted to get some suggestions from others who have done this conversion.

If I remember correctly, we had bought a new 164LS 24V Alternator but the brackets that we had would not fit correctly so we decided not to use the 164LS alternator. We used our old 2.5L 12V and had this installed since it was earlier to fit. Then, the bracket broke and we had Phil make another one for us.

I just spoke with Phil and he said that he did not remember what type of Alternator that we had but went through options on how to correct this problem. I am posting some pictures just to determine if we have the original 2.5 L 12v Alternator. I was hoping that someone could look at this and confirm:

1). It is a 2.5L 12V Alternator.
2). That we have a Flat Belt system rather than a v belt system.

cchan · Post by **cchan** » Sat Jun 06, 2009 10:44 am

Our Options are:

1). Have the 2.5L 12V alternator rebuilt but since the amps are I think between 50-60 and have it upgraded to 70 AMPS minimum. This would be the easiest fix since the brackets and pullies are already fabricated. However, what shop could do this for us. Does any one know a good shop that can do this for us?

2). Purchase a 3.0L Milano Alternator which will already have the 70 AMPs that we need. We would just have to figure out how to bolt on the new pulley from the old 2.5L 12V since we were told that the 3.0 Milano Alternator has a V belt and our 3.0L 24V has a flat belt. This is probably the next easiest way to go.

3). Get the 164LS alternator again and install this onto our system. This probably is the hardest way to go since last time I remember that the 164LS alternator is much larger and we were having clearance issues as well as needing to fabricate new mounts and brackets.

4). We also discussed that maybe we can souce a BMW Alternator that could be a direct bolt in to the 2.5L 12V alternator but have 70amp +. This would be more readily available and possibly a cheaper fix.

We would appreciate any suggestion and comments to our situation and would also welcome any other options as well. We definately need more that 50 AMPs of the old 2.5L 12v Alternator since we will be upgrading the headlight system as well as putting in some type of Stereo system as well.

Thanks again for all the help.

Giuliettaevo2 · Post by **Giuliettaevo2** » Sun Jun 07, 2009 5:10 am

I would take off the old alternator and take it to a european car wrecker and look for a suitable replacement. If you find one you can have that rebuilt or you can order a new one if the wrecker knows the make and model of the donorcar.

BMW is a good place to start looking.

If size is a problem look at Japanese cars, they use much smaller ones. A new bracket will be needed though.

Good luck with it!

Post by **Zamani** » Sun Jun 07, 2009 9:00 am

I think the early 80's 7-series alternator (not E32 7-series, the earlier ones) will almost fit, may need some small modification.

cchan · Post by **cchan** » Mon Jun 08, 2009 11:20 am

Thanks for all the suggestions from Zamani & Giuliettaevo2,

We were at the Porsche concours on Sat @ Partsheaven in Hayward and ran into our friend that helps Alfa owners. We have determined that the Alternator is not charging and this is our problem. We determined this after checking with the Volt Meter. We are going to pull the Alternator during lunch and have it rebuilt and upgraded.

Jeff @ Riteway in San Francisco will help us do this. It will cost $118.00 if we can use the same housing, etc. If we need to get another housing, and additional parts it will cost around $200.00. We will not know this until we have Jeff look at the alternator.

We are hoping to upgrade to 100 AMPS but were told that 70AMP should be enough to handle the upgraded headlight system and a stereo system without alot of amps.

Thanks for all the help on solving this issue.

cchan · Post by **cchan** » Mon Jun 08, 2009 5:12 pm

We pulled out the Alternator today at lunch. It was straight foward in terms of the 2 bolts securing it and we did not have to touch the bolt holding our custom bracket. The only small issue was that we needed to partially drain the coolant since we could not remove the alternator without disconnecting the upper coolant hose. Therefore, it is really tight in this area.

We inspected it and there are no markings at all so we have no basis for what type of Alternator we really have. We do know that it should be one for the 2.5L 12 valve and will have this confirmed hopefully by Jim tomorrow. I am posting some pictures of the Alternator showing that there are no names or marks which make this alot harder to figure out what we have. You can also note the pulley being changed from the original V belt to the flat belt system to work with the 164 LS 24 Valve motor. We looked the the original 2.5L 12 Valve engine over the weekend and confirmed that the 2.5L 12 Valve belt system is V belts.

Also, we are posting a picture of the belt for documentation for the belt numbers, size, etc for referrence. We might as well get an extra one now and keep it for future use.

cchan · Post by **cchan** » Tue Jun 09, 2009 7:47 am

Hello,

Dropped off the Alternator to Jeff this am. He really knows his stuff about Alternators. We are having our alternator rebuilt and will be upgrading the Stator to 95 AMPS along with rebuilding all the Bearings, slip rings, voltage regulator, brushes, etc. We are also having him put on the Fan that we were missing and shaving the shaft. We need to do this so the pulley will stay in the same postion and will line up correctly when we install it again.

The original 2.5L 12 Valve Alternator that we have is a Bosch #14395 65 AMP Unit.

There is also another Alternator that is a Bosch # 13248 70 AMPS. This must be the Milano one that Phil was referring to.

The original 95 Alfa 164LS 24 Valve Alternator that is now our engine is a Bosch #13617 120AMP unit. As we know, this is an entirely different casing, etc which is much larger and therefore harder to set up with our conversion.

We could have went with a swap and this would have cost of $118.00 and we would keep the same 65 AMPS. The other alternative was to update to 120 AMPS with the same housing, etc and this would have cost of $220.00. We went the middle gound and will spend $168.00. 30 more AMPs should be enough for the updated electrical items that we will be installing.

Hope this help anyone who is either doing or thinking of a 24 Valve Conversion. Hopefully this is the last bug in the system and if we still have alternator problems we are considering making a heat shield to further insulate it from the headers.

cchan · Post by **cchan** » Wed Jun 10, 2009 3:52 pm

Hello,

Well we picked up the rebuilt alternator today and determined that the diodes had failed. Most likely it over heated but who really knows. The alternator is close to the headers and it did not have a fan. We spoke with Jeff and looked at the alternator parts just to get an idea of how it works. Here are some pictures of the old voltage regulator, diodes, bushings, and 65 AMP stator.

Besides the upgrade to 95 AMPS we had a new Fan installed and resized the pulley to fit in the same position that it did without the fan. This cost an additional $28.00. We just did not want to take a chance that it would be off 1/8 inch and have the belt not line up. We installed the new Alternator into the Alfa and the Alternator warning light went off. Hopefully this fixes this issue. If the alternator breaks again then we will custom make a heat shield like we did for the starter.

Thanks for all the suggestions and help and we solved this issue.