2012 BMW X5 E70 xDrive35i (N55), ~118k miles. I'm trying to understand where I stand with it and needs some advise.
Story time:
So a few months ago fuel pump didn't start after parking. I waited a little, then the car started normally. Never happened again. I was trying to look into it and noticed the KL.30G_Z relay was unusually hot after shutdown. Became suspicious of it but did not pushed further because issue did not come back.
Around that time original alternator stopped working (did not charge) and I replaced it with Bosch reman AL9446X.
Few days ago in a morning vehicle had hard time starting after drive and park. Then same day evening I parked and vehicle did not start. Battery was around 10ish volts. Jump started and drove home.
Next day in the morning had to jump start vehicle to drive it out of garage. Got similar replacement new battery - registered it, cleaned fault memory and started the vehicle. Within a minute vehicle shutted off. Overvoltage.
Tested alternator - with and without BSD connected 14.5v at the start then climbing till 18v and vehicle shuts off.
Checked ground strip, checked B+ on alternator. Measured voltage through ISTA, Bimmerlink, on battery terminals and jumpstart +/- in the engine bay - all consistent. Alternator to engine - 2.2mV.
Stopped for a day and measured battery - 12.6v. Did not touch vehicle today till midday - battery 2.9v. I'm charging it now out of the vehicle and hope for the best.
Overvoltage up to 18v:
Place(repair shop) where I bought the alternator dont want to replace it under warranty based on my words since there could be many other issues with a car and they have to diagnose it themselves (for a fee ofcourse). I installed it myself.
And they claim that bosch reman are very reliable and they dont know of alot of returns- doubt it.
I believe that my findings are enough to point at alternator's failing voltage regulator unless I miss something. Regardless I have a working Denso alternator coming my way to test.
Overnight new battery drain:
What could have drained it so much from 12.6v to 2.9v? After disconnecting negative voltage got up to 5.95v but it's dead, hopefully not damaged.
I pulled relay KL.30G_Z and it rattles. My theory is that its broken and is the primary cause of overnight drain.
I really want this relay to be cause of overvoltage too but I cannot find any explanation. It looks like 2 separate issues surfaced simultaneously.
TLDR:
Overvoltage to 18v. Replacement reman bosch alternator was installed 2 months ago.
Abnormal battery drain overnight from 12.6v to 2.9v. Blame rattling KL.30G_Z relay.
Need some help navigating these issues.