Yup this happened to me with my 73 220D.  Definitely voltage regulator.  On 
that car it is a separate unit.  On yours, considering the problems that you 
are describing you might be better off just buying a factory reconditioned 
Bosch alternator.  Try Rusty at buymbparts.com


--- On Sat, 2/21/09, Fmiser <[email protected]> wrote:

From: Fmiser <[email protected]>
Subject: [MBZ] Stinky car
To: "Mercedes list" <[email protected]>
Date: Saturday, February 21, 2009, 12:09 AM

I have had an odd experience this last week.

I take my '82 240D the car on a 250 mile trip.

10 miles into it I notice a terrible stink! Sort of like fried
eggs that sat in the sun and spoiled. Toward the end of the of
the trip I notice my two-way radios have an alternator whine
in the receive audio.

The stink had now gotten so bad that when I fueled, just
standing down-wind of the car was unpleasant. I tried to
figure out where the smell was coming from. It sort of seemed
to be coming out the heater vents, but not really. It also
seemed to be worse sitting still than on the highway.

I had no clues - so I ignored it! *grin*

My wife took the car a couple days later. If anything, the
stink was worse. When she got home, I park the car outside
with the doors open to air it out. I decided to spray lysol
into the heater air intake to maybe do something about the
smell.

I ended up replacing the starboard wiper blade pivot. No, that
had nothing to do with the stick! But to get to the intake, I
pulled off the wiper box cover. While doing that I discovered
the drain for that pivot had clogged and the pivot housing was
in _really_ bad shape. 10 minutes later I had a one pulled
from my private parts yard. I spray a bunch of Lysol in the
intake, ran the fan, and put it all back together again.

Still no conclusive data on the source of the smell.

A couple days later later the car won't start. No, it's not
from having the doors open while airing it out. Good guess
though - I turned off the dome lights. The block heater was
plugged in and it wasn't very cold. A jump start got it
going. Turned it off once in the middle of the 60 mile trip
and it cranked slow when it started - but it did start. Didn't
turn it off for the other stops. *smile*

Well, a stink I'll ignore, but not starting is a bit more
serious. And I have toy - er, _tool_ to help track down the
problem. There has been a bit of "no start" history with this
car.

About 2 month ago I had a bad solenoid on the starter on this
240D. Since then it's been starting fine. Then about 2 weeks
ago it didn't start. Maybe I left the trunk open too long, or
something like that. Most annoying was the fact I was 700
miles away and it wasn't me that had to use the old truck to
jumpstart.

The interior light turned on, the glow relay click, but that's
about all it would do. Less than 5 minutes on the jumper
cables (4 AWG) and it started fine.

Fast forward. First step in a no start is to check battery
voltage. 4.9!!! No wonder it didn't start! Hook up the charger
to the 4 year old battery. About an hour later I disconnect
the changer, let it rest for a couple minutes and check the
voltage again. 5.2 Volts.

About then I notice a bubbling sound from the battery. I start
to get a glimmer...

I lean over to make sure that's where the sound is coming
from. 

I happen to breath in. (I do that rather often...)

The stinky smell!!!! It's the battery!!

I open the vent caps to see the "water" level. It's so low on
_every_ cell I can't see _any_ liquid.

So did the battery just die, or did the voltage regulator kill
it? 

With a jump, I started the car and measured 17 V at idle. I
_seriously_ overcharged battery, boiled to death!!

About 8 months ago the brushes wore out and I replaced the
brush/regulator assembly. Oh well. I removed the screws and
found that one ear had broken off, the other was cracked. So
the problem was a mechanical failure.

I have a new-in-the box regulator/brush unit on the shelf, so
stuck it in. I noticed that it didn't seat all the way in when
the screw holes lined up.

It's a 240, so there's a lot of room under the hood compared
to a 300 turbo - but still not enough to see, so I remove the
alternator. With it sitting on the work bench with bright
overhead lights I could see the hole in the alternator housing
wasn't big enough for the protrusions on the bottom of the
brush unit.  In other words, it didn't fit! I wanted a second
opinion. I got that from one of the parts cars. Same
thing. And both of these were shaped the same as the
now-broken one. 

What to do?  What I did was took the parts car part and a file
and grind wheel and made it fit.

And I bought a new battery...

So the moral of the story is, check your windshield wiper
drain to make sure it's not plugged.

Actually, I'm guessing the alternator must have come from an
older car and the regulators are _almost_ interchangeable.

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