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Old 10-19-2018, 08:09 PM   #1
TSI
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Alternator upgrade--rewinding?



As some of you know, I've a S62 in my E34 540.

I just realised the S62 has a 120A alternator, whereas the E34 540 originally had a 140A. My lights flicker at idle.

I don't think there's a bolt-on upgraded alt, so I'm leaning towards having it rewound with a few more coils.

Does anyone know of a place that can do this?
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Old 10-20-2018, 09:02 PM   #2
jabela
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What about upgrading the lights to lower power, more efficient units? Like HID or LED?
Or what about a higher capacity battery or deep cycle unit?
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Old 10-20-2018, 10:53 PM   #3
SickFinga
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Your light don't draw 120A. The issue is most likely with a bad ground somewhere or your S62 alternator going bad.
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Old 10-22-2018, 10:01 PM   #4
TSI
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Indeed, the lights themselves aren't 120A, but combined with all the other E34 elements, plus the S62 swap itself (I added a whole CANBUS harness with a couple more sensors), an electric fan conversion and a few electrical add-ons, I think the lights flickering are likely a symptom of insufficient voltage output, as they even out as soon as I rev past 1000.

Hence my thinking I need more amperage, at least at idle. Apparently the M54 alternators are bolt-on.
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Old 10-22-2018, 11:22 PM   #5
5style
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Do they flicker with the engine off? It could just be the voltage regulator on the Alternator. Also, Check your grounds!
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Old 10-23-2018, 10:56 PM   #6
TSI
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No, only at idle. I have good voltage with engine on and off
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Old 10-24-2018, 02:20 AM   #7
SickFinga
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Quote:
Originally Posted by TSI View Post
Indeed, the lights themselves aren't 120A, but combined with all the other E34 elements, plus the S62 swap itself (I added a whole CANBUS harness with a couple more sensors), an electric fan conversion and a few electrical add-ons, I think the lights flickering are likely a symptom of insufficient voltage output, as they even out as soon as I rev past 1000.

Hence my thinking I need more amperage, at least at idle. Apparently the M54 alternators are bolt-on.
My money is on either poor ground, bad voltage regulator or brushes. Yes, 540i came with a 140a alternator, but 6cyl cars had an 80a alternator. The chassis alone doesn't seem like it requires too much juice, judging by the 6cyl cars. So if your lights are flickering without much load, I'd say the issue is not in the missing 20amps.
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Old 10-24-2018, 01:08 PM   #8
TSI
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Ok, will try to check those. The engine ground cable is one of those flat braided ones, I'll try to get a proper one once I fix this latest failed starter.
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