S40 (New) Electrics : Advice on Alternators and fitting please

[UKTech]

Hi folks

Hope someone can help me with my problem today.

I’m quite sure that my alternator has burnt out, it had wisps of smoke coming from it, it was very hot and it stunk of burnt wiring, trust that it’s enough to go by and confirm that it’s burnt out.

Q1. Could I have caused this myself as I had a headlight cluster out yesterday to replace a marker bulb and put the cluster back in again. No messages on the dash earlier today and everything lights wise working fine, but as I drove home later this afternoon I had a message saying that I needed ‘An electrical service needed urgently’ and the battery sign lite up, I carried on driving another 2 miles to where I could park safely and called ‘Green Flag’ out to have a look, they put the car on a bogey and took me home as that is where I requested to go. Can I just say that their service was brilliant. What else would have caused this thing to burn out?

Q2. If indeed I do need a new alternator is the part number 36000599 correct, my car is a 2004 (2004/2005 model) Volvo S40 2Ltr S.E Diesel, manual, R.H.D.

Q3. Can this replacement job be done at home if I acquired a new alternator, either Volvo make or 3rd party?

Q4. My old Vida advises that the new alternator is 150Amp and is an upgrade from the original 120Amp and that I would need an upgrade to the software, Does this software upgrade need doing when the new alternator is fitted or can it be done at a later date as my main stealer is an 80 mile round trip away from me.

Q3. If I do need to obtain a new alternator (from whichever source I chose as above) can anyone advise as to the approximate price of such said item and what would be the approximate fitting time and cost at the main stealers?

Q4. Is there anything else that needs changing at the same time such as new belt, new nuts etc. etc.

Q5. Can the car be run at all without the alternator, such as to get me to the main stealers some 40 miles away for instance?

Any other suggestions would be very welcome as I’m obviously off the road at the moment. Keep ‘em clean please ;-)

Hope someone with the knowledge can help.

Thanks
UKTech

[Daim]

The car run with no worry without an alternator, but you will flatten your battery and if really lucky ruin it and need a new one. Especially since your diesel engine isn't a mechanical dieselengine like they used to be but fully electrical.

[UKTech]

Thanks Daim

I know I ran it for 2 miles but it was burning out as I travelled. The battery is a new Bosch one, only fitted a couple of months ago.

The battery is quite flat now, would it be wise to disconnect it and charge it fully now, then reconnect it say tomorrow or Thursday?

[UKTech]

Can anyone else answer for me please if you can.

Thanks

[Bendolfc]

1) Don't see how you could cause it by changing the bulb, the alternator is a known weak point on these so probably just coincidence.

2) Not sure

3) If you are capable of doing it yourself then no reason why not, have a read through some older alternator threads and there are tips on how to do it such as not removing the fuel filer but just shifting it out of the way etc.

4) If you had the 120A fitted, you should fit the 150A, it will require a software update, someone on here had previously said they fitted the 150 then took it to a dealer to update the software so it should be possible.

5) Not sure I'd fancy your chances of getting 40 miles without it but if you try then make sure to put the lights on sidelights only and avoid using any electricals.

[GazT4]

You wont get far without the alternator, so dont try that.

As above, its a known common component to fail so more than likely a coincidence.

[UKTech]

Thanks everyone, the advice was just what I needed.

I've ordered a new alternator and it should be here tomorrow, pal fitting it on Monday and doing an oil and filter change at the ame time.

Sorted.

[138gat]

Hi, Took this off a post when I changed mine last year, hope it helps
Power System Service Urgent!!
________________________________________
Hi All

I had a message 'Power System Service Urgent' with battery lamp symbol showing every so often on my 2004 S40 2.0 diesel. Whe engine was turned off and restarted the warning would go away. Regardless I measured voltage when engine was off and it measured 12.4V. With engine started it measured flat 14.2V. The regulator or diodes or winding at fault God only knows.

Exchange alternator unit 150AMP Lucas brand from Eurocarparts was £167 but you have to hand over your faulty one.

The car voltage with new unit is 14.45V and car feels lot crisper and faster - I don't need even press the accelarator and she flies. No warning sign on dashboard gulp yet!!

Volvo or other garages charging £800+ for this when you can do it for only your time (2hrs max).

Car feels lot faster now too!!!!

The warning was intermittant on the dashboard and I have noticed car felt underpowered recently. I have thus taken the plunge and replaced the alternator. If you want to do the replacement its very easy all you need is a Haynes manual and well in the capability of a home meachanic.

To replace alternator:

First disconnect the battery leads.
Raise driver side off ground and put on stand and chock wheels with handbrake up. I always use jack as secondary support to be on the safe side.
Next remove plastic lid off engine.
Next remove protective shield under car please be careful and make sure car is supported very well.
Next remove serpentine belt by using ring spanner on tensioner to release tension making note of how it is fitted.
Next remove metalwork around fuel filter casing.
Next unscrew fuel filter casing and pull up casing with hoses still attached. You can leave in position if you wish and work under it.
Next remove small black cap off alternator and unbolt red lead.
Next remove connector from alternation which has small leads.
Next unbolt alternator bolts (4 bolts) with 16mm ring spanner and 16mm socket. Careful not to chew off any heads. You will have to access lower bolt from underneath
Next loosen allen key bracket at bottom of alternator whilst supporting alternator.
Unbolt allen key spacer off old alternator before handing over for exchange.
Remove alternator and replace with new one in reverse process.

Do not overtighten any bolts specially on the alternator otherwise you will breakage and headache!!!! You have been warned..........easy tiger!!

I hope this article gives hope to the beginner as you do not need to be an expert!!

Cheers
HEAVY747

[UKTech]

Thanks, much appreciated.
I've had a quick look and read your instructions and it all looks easy enough to do.
I've ordered a new unit for delivery tomorrow as I've mentioned above and my pal will appreciate the instructions on Monday when he is going to fit it.

Great job everyone, thanks to all who contributed.

UKTech

[quinno]

If it helps. I have a 2004 V50 2.0d. Same warning mesage came on.
Q3 At an independent (not a volvo specialist) I paid £191 +vat for the replacement altenator and £43 + vat for the altenator belt. Looking under the bonnet the new one is made by Denso. The old one was also made by Denso. I have not checked on what amps the new one delivers.

Q4 the 'altenator belt' was recommended. Having had the car since new in 2004 i don't recall the altenator or this belt being replaced so I had it done while the car was inthe garage.

I take it that the power steering is electrically assisted, when the warning message came on the steering became heavier. Is this consistent with the altenator not charging the battery or some form of limp home capability.