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Maybe its whatever regulates the alternator output rather than the alternator itself.
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I Doubt you have a leak now. my comment was meant to mean the acid. Is still active. If not washed away properly or made inactive. a thin coat remains..causing this to happen.may be wrong here. But think thats what has happened
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Steve
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This often happened with my old Volvo 440 with cat and carburettor when I stopped at traffic lights and the exhaust fumes were lingering around the car. I had to reassure my daughter, who was looking daggers at her children in the back seat. "No darling, disgusting though they usually are, its not the kids this time".
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I have always believed that the 'rotten eggs' or Hydrogen Sulphide smell came from the catalytic convertor being 'poisoned' by someone using leaded petrol. Of course cars with convertors should only be run on unleaded fuel. I do remember that some of the supermarket fuel in the UK did smell quite sulphurous, even the unleaded variety.
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I think perhaps the new battery has been overfilled with electrolyte and as mentioned it has expanded out. Have had the same problem myself. Take out the battery and slosh the area over with a bicarb solution to neutralise the acid.Then clean and replace battery.
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As an ex-chemist, the eggy smell (correctly identified as Hydrogen Sulphide - H2S) if I remember correctly, is produced whenever a strong acid was heated with Iron (I think because of naturally occurring Sulphur in the Iron). Could it be that the smell is battery acid reacting with some Iron somewhere?
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Google found this.
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ROTTEN EGG SMELL FROM CATALYTIC CONVERTER
The sulphur smell from the exhaust, is actually caused by running the engine/cat convertor slightly lean for long periods and then running under a rich condition (ie going up a hill under heavy load) This is when the sulphur smell (rotten egg) is produced.
Under relatively lean conditions, the sulphur found in gasoline is converted to sulphur trioxide, then during the rich running condition the sulfur trioxide is converted into hydrogen sulphide (rotten egg smell) within the catalytic converter.
Audi of America issued a service bulletin Group 24, #92-04 which detailed this problem. They list the cause as : the gasoline sulphur content and the characteristic of catalytic convertor to store sulphur compounds and release them during rich engine running conditions.
Switching gasoline brands may help. The Oxygen sensor may also need to be replaced to correct a fuel injection mixture problem
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Some very interesting ideas, & I guess there are some things that I can try, like cleaning the area, which is not going to break the bank.
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