Second post today :bang:

Daughters car dropped the gearbox linkage last night so bodged that tonight.

Whilst fixing this she said dads there’s a smell when I run the car ??

Not believing her after rebuilding the geAr linkage left it on tickover ......now eating humble pie ?

It sure smells and it smokes to boot wtf?.

It’s eminating from the aux belt side of the engine- I replaced the aux belt in March with a Gates belt so I know that’s new . Timing belt and water pump also done in a July. For the life in me I cannot figure out where this smell and smokes from. It ain’t the clutch or release bearing as just sorted that out, plus she said it’s been doing it “a while but forgot tell me” ?

Anyone a theory at all - all pulleys look like there moving freely on the aux belt. Thought about dropping aux belt and starting car up to see if it still smokes and stinks just to start ruling stuff out.

Engines not overheating, no sign of mayo in oil cap or dip stick, no coolant loss or discoloured no steam from exhaust- help I’m running out of patience:slayer: but not sure if it’s daughter that’s going to get it or the car ??

Cheers all as always

What does it smell of? First thought breather hoses to air box?
Use a very bright light when dark to try and pin point the general area, though the exhaust flexi is near that area?
Does the car have a.c.? Clutch on compressor?

Eh up john202020

It smells of plastic , acrid smell, not loads of smoke just a whiff

Did exactly that got the inspection lamp out and that’s when I noted the actual smoke, you can see it in the beam.

Exhaust is new - changed that as well about a month ago

Interesting comment re the ac - what you thinking

TTR said:

Eh up john202020

It smells of plastic , acrid smell, not loads of smoke just a whiff

Did exactly that got the inspection lamp out and that’s when I noted the actual smoke, you can see it in the beam.

Exhaust is new - changed that as well about a month ago

Interesting comment re the ac - what you thinking

Click to expand...

Was thinking burning a.c. clutch but was a long shot if it's working ok and it wouldn't be a plastic smell, look for any pipes wires etc touching anything hot? Maybe?
Take a look at the starter cables and alternator ones?

Mmmm

It’s a puzzle that’s for sure, going to strip aux belt off and run car on tickover to see what happens.

Will be able to see if pulleys are free or if there’s any play

If no smell then it rules those components out, I’m struggling on this one.

FFS it’s just been one of those weeks with this car:bang:

Anyone feel free to throw in any ideas the more I have to go at the better

Will update this thread as I go

Cheers

Eh up all,

Right - today I stripped out the aux belt and ran the engine - no noise or hint smoke at all.

Soooo my take from this is what ever is causing the smell and smoke is attributed to to aux bel.

On that basis I checked the belt which appeared in good condition other than some rub marks on the edges.

I checked the tensioner by hand and felt tight and no rumbling bearings.

AC compressor felt same , no play .

Alternator is my main worry, no sign of much end float on the pulley, but did not sound “ right” when I turned by hand but not to the extent I would have thought would cause an issue. Other observation was the casing was HOT , not sure if this is normal or not ?

Put belt on started car and noise and smell back, no smoke this time.

What’s anyone’s view on this - start with changing the alternator and belt for good measure and work cheapest to most expensive.

Also anyone have a how to on replacing the alternator assembly, looks tight but doable without removing anything major


Cheers for any replies - been stuck under daughters car for best part of 4 hours all in today:bang: ain’t her fault really but I’m getting too old for this beer time:slayer:

Put a bog standard belt on noting for cars with a.c., just how hot was the alternator ? Too hot to touch? Could try load testing it, turn on rear screen headlights fan etc if possible measure the voltage see if the stress causes smoke?

John202020

Evening, I’m struggling with electrics not my strong point as this forum may know better with spanner# ( and hammers)

Alternator was hot - not that I’m an expert but common sense said it’s too bloody hot and ain’t normal

I’m edging my bets that’s the problem, but it’s guess work ( might opt for a punt at a scrap alternator and bang it on, cheaper than an hour in the garage on diagnostic for her)

Useless with owt with gauges ..... cannot fathom out wHat it’s telling me.

No smoke today and put on fullload, fan, screen, heater, etc

Wonder how hard a job it is dropping the alternator out, looks a tight fit in fairness, I ain’t no lightweight and fingers like pork sausage

But will try and save the little one some money if I can.

Thanks for the input, keep the ideas coming

Cheers

Hey buddy. A hot alternator is not normal. Seems that the windings are breaking down inside causing a short - high current - melting of insulation - smoke and smell etc etc.

That would be my first thing to change over, albeit a tight fit. Also please check battery voltage with car running to be sure it is not overcharging because that could damage other electronics which would be a total pain!

I would suggest a replacement alternator second hand will be fine. I've replaced about £1500 worth of parts on our car, though not engine related bar a cooling pipe and plug leads oh and breather pipes and slave/master clutch cylinder

Stevo123

Cheers for that, I thought as much but ain’t no sparks

John202020

Cheers I am looking for a used unit on eway, just need to make sure I get the right one

I’m more convinced now it’s the alternator- Stevo post makes sense to me, I’m no electrician always been a weak point for me so need to be reassured before I crack on with this.

Still trying to get info on dropping it out, I’m not sure if it will come out without moving driver shaft?

Seems to be a tight fit with one bolt behind the ac pump.

If I can pick one up for £40.00 or so and I can fit it will save the little one a small fortune- then she can spend it on hair, nails, etc .....:bang: as those of you with daughters of an age will know ....

Cheers all

This might help

My money is on the alternator. If you remove the belt and man-handle the pulley from side to side, it should have no play in it. If it wobbles, moves in and out on its "axle" or feels stiff/grainy to rotate then it's knackered.


Ralf S.

Ralfs

Did that Saturday, no obvious sign but felt “odd” when I spun it by hand, also bl88by hot to touch.

It’s my best bet now too.

Just looking to confirm what the part number is for mine and seeing if I can get one refurbished or used via e8sy.

Also still working on how to get the thing out. Looks as if I need to drop a drive shaft!!!!

Would really like not to but let’s see.

Cherry all for the inputs on this - I will crack it orbit will break me!

If the girl is going to keep the car for ages (since it's going to be an "old" car with all new parts on it soon) then also check out a brand new alternator.

An alternator is a complex beast, with built-on regulator/rectifiers and the like, which are just solid-state electronics that can decide they're tired of life and pack up at any moment.

Given the "pain" is in the fitting, more than in the buying (c. £130 for a new Denso, if you use Eurocarparts etc. and one of their perennial discount codes) then it might be worth fitting a new new one, if you can't find a low-mileage/great condition seconda-mano one.

I've changed alternators on a Cinquecento (Fiat engineered a curve into the inner wing so the alternator dropped down and slid out through the cut-out) and a Stilo (driveshaft out jobbie..) so you might find a route out (below would be my guess) or you might not.

But as you remove the driveshaft you'll also be able to check out the condition of the CV joints, boots and bushes.. and the brake pads... so you'll be better prepared for the next bit of maintenance and be able to judge when it might be (if your daughter's car is like mine, everything seems to wear out between December and February).


Ralf S.

Note, the Denso is £20 cheaper on Carparts4less

Also note there is several different alternators 70A or 90A, cars with and without stop start and 4 or 5 ribs on the pulley so careful choice is required, you can get a new alternator for as little as £86 after exchanging the old one?

Ralfs john202020

Cheers for the advice, I know that the alternators differ so just tracing the codes and types.

Elected for a refurb or new depending on cost, if I’m fitting it I ant stripping all that out for a used on to go wrong or not fit.

All the other running gear is spot on as I did the brakes, cv rubbers etc late last year when I bought this.

Will keep you posted, cheers for the help thus far.

Spanner’s out again this week

Replaced my alternator twice due to noise. The 1st one was a recon part which took out the rear bearing. The latest one was off a KA on ebay for £30. The bearings are about £5 each and not hard to fit if you have the tools and want to save the most money. Worth saving if the armature is not worn.

Eh up all,

Well after pi55in8 around I diagnosed the alternator is FUBAR

So spent the best part of this morning trying to get the thing out - :bang:

Gave up after dropping drive shaft re assembly and dropped into a mate of mine with a 4 post.

20;minutes later having loosened the engine mount to get more space got the bugger out and replaced :slayer:

Runs sweeeeet now.

Hats off to all those who manage this on jacks, maybe I was doing something wrong but could not get it out


Anyway all’s well and only cost me a set of tinnies


Thanks for all the input - little ones sorted , cars safe and I’m having a beer

Hope this helps someone else

Will be back with next problem shortly- won’t be long with this little car.......

Cheers all

I'm wondering about replacing the whole rear axle, that too will be quite a job on the road outside our house.