dremd
Veteran Member
- Joined
- May 31, 2007
- Location
- South Louisiana
- TDI
- 06 sprinter. 03 jetta wagon premium with 6 speed ALH swap, 14 JSW
First off let me apologize for not taking pictures.
My goal here is to save people like me about 30 minutes when changing alternator brushes without removing the alternator from the car. The below is very obvious once you have already removed he brushes, but prior it is a bit of a mystery.
This procedure can all be done from the top without jacking the car up ore removing the skid plate assuming you don't drop any tools/ fasteners. Even if you do chances are you will be able to reach them from the top.
Back of alternator to me is drivers side (hold over from longitudinal engine mounting).
To remove brushes.
0) disconnect battery, don't argue on this one, your wrench will have + 13 volts 150 amps (fuse size) on many occasions.
1)Remove any aftermarket oil pressure sensors that get in the way of the plugs on back side of alternator (ask me how I know).
2) remove heavy Alternator wire with 13mm ratchet and the 2 pin connector both from back of alternator using your fingers and maybe a bit of help from a flathead screwdriver.
2) remove alternator wire (harness to battery) holder at bottom of alternator using 8 mm, I used the deep 1/4" drive on a small ratchet. The steel bracket has to be wiggled quite a bit to get it off of the stud.
3) remove secret #2 Phillips bolt at bottom of alternator (previously coverd by wire holder) holding black back cover over the regulator/ alternator.
4) remove the 13mm nut below the first 13mm nut that you removed to get the heavy wire off. Here is where I poked for a good 15 minutes after hearing that you don't have to remove this, you do.
5) The cover should wiggle off at this point. If it doesn't, figure out why.
6) remove 15mm nut toward the pulley (same stud) of the 13mm nut you already removed (same orientation).
7) remove 3 #2 Phillips bolts holding regulator to alternator (2 mounts, 1 terminal).
8) remove brush/ regulator assembly by sliding up.
9) re-install in reverse, note that the new brushes are somewhat delicate and must be compressed on to the communicator.
Enjoy your new found voltage.
I purchased a genuine Bosch regulator from an eBay seller named American Engines (I know, weird). Was about $70 and arrived well packaged in 3 days.
Below is Edit
One I purchased (I know link will die) http://www.ebay.com/itm/160848443559#ht_1807wt_1180 Part Number F-00M-145-200, OR F-00M-145-209
Copy / paste from Auction
GUARANTEED to fit:
VOLKSWAGEN
LT 2.5L TDI, SDI 1998-ON
TRANSPORTER 2.5 TDI 1998-ON
TRANSPORTER 3.2L 2003-ON
CALIFORNIA 2.5L TDI 2001-2003
CARAVELLE 2.5L TDI 2001-2003
MULTIVAN 2.5L TDI 2001-2003
Dimensions
12 Volt
14.5 Volt set
A-Circuit
L and DFM
Internal Fan Units
Interchanges with the following original numbers
BOSCH F-00M-145-200, F-00M-145-209, F-00M-145-225, F-00M-145-350
MERCEDES BENZ 003-154-24-06, 003-154-53-06
PORSCHE 000-043-206-37
VOLKSWAGEN 038-903-803, 038-903-803B, 038-903-803E, 038-903-803EX
Alternator Numbers
BOSCH 0-124-215-006, 0-124-315-030, 0-124-325-057, 0-124-325-074, 0-124-325-075, 0-124-325-125, 0-124-515-001, 0-124-515-013, 0-124-515-015, 0-124-515-038, 0-124-515-039, 0-124-515-042, 0-124-515-062, 0-124-515-073, 0-124-515-083, 0-124-615-006, 0-124-615-014, 0-124-615-016, 0-124-615-026 VALEO TECH 572906
VOLKSWAGEN 021-903-025T, 021-903-026, 021-903-026B, 028-903-031, 036-903-024E, 037-903-026B, 037-903-026C, 074-903-025J, 074-903-025S
My goal here is to save people like me about 30 minutes when changing alternator brushes without removing the alternator from the car. The below is very obvious once you have already removed he brushes, but prior it is a bit of a mystery.
This procedure can all be done from the top without jacking the car up ore removing the skid plate assuming you don't drop any tools/ fasteners. Even if you do chances are you will be able to reach them from the top.
Back of alternator to me is drivers side (hold over from longitudinal engine mounting).
To remove brushes.
0) disconnect battery, don't argue on this one, your wrench will have + 13 volts 150 amps (fuse size) on many occasions.
1)Remove any aftermarket oil pressure sensors that get in the way of the plugs on back side of alternator (ask me how I know).
2) remove heavy Alternator wire with 13mm ratchet and the 2 pin connector both from back of alternator using your fingers and maybe a bit of help from a flathead screwdriver.
2) remove alternator wire (harness to battery) holder at bottom of alternator using 8 mm, I used the deep 1/4" drive on a small ratchet. The steel bracket has to be wiggled quite a bit to get it off of the stud.
3) remove secret #2 Phillips bolt at bottom of alternator (previously coverd by wire holder) holding black back cover over the regulator/ alternator.
4) remove the 13mm nut below the first 13mm nut that you removed to get the heavy wire off. Here is where I poked for a good 15 minutes after hearing that you don't have to remove this, you do.
5) The cover should wiggle off at this point. If it doesn't, figure out why.
6) remove 15mm nut toward the pulley (same stud) of the 13mm nut you already removed (same orientation).
7) remove 3 #2 Phillips bolts holding regulator to alternator (2 mounts, 1 terminal).
8) remove brush/ regulator assembly by sliding up.
9) re-install in reverse, note that the new brushes are somewhat delicate and must be compressed on to the communicator.
Enjoy your new found voltage.
I purchased a genuine Bosch regulator from an eBay seller named American Engines (I know, weird). Was about $70 and arrived well packaged in 3 days.
Below is Edit
One I purchased (I know link will die) http://www.ebay.com/itm/160848443559#ht_1807wt_1180 Part Number F-00M-145-200, OR F-00M-145-209
Copy / paste from Auction
GUARANTEED to fit:
VOLKSWAGEN
LT 2.5L TDI, SDI 1998-ON
TRANSPORTER 2.5 TDI 1998-ON
TRANSPORTER 3.2L 2003-ON
CALIFORNIA 2.5L TDI 2001-2003
CARAVELLE 2.5L TDI 2001-2003
MULTIVAN 2.5L TDI 2001-2003
Dimensions
12 Volt
14.5 Volt set
A-Circuit
L and DFM
Internal Fan Units
Interchanges with the following original numbers
BOSCH F-00M-145-200, F-00M-145-209, F-00M-145-225, F-00M-145-350
MERCEDES BENZ 003-154-24-06, 003-154-53-06
PORSCHE 000-043-206-37
VOLKSWAGEN 038-903-803, 038-903-803B, 038-903-803E, 038-903-803EX
Alternator Numbers
BOSCH 0-124-215-006, 0-124-315-030, 0-124-325-057, 0-124-325-074, 0-124-325-075, 0-124-325-125, 0-124-515-001, 0-124-515-013, 0-124-515-015, 0-124-515-038, 0-124-515-039, 0-124-515-042, 0-124-515-062, 0-124-515-073, 0-124-515-083, 0-124-615-006, 0-124-615-014, 0-124-615-016, 0-124-615-026 VALEO TECH 572906
VOLKSWAGEN 021-903-025T, 021-903-026, 021-903-026B, 028-903-031, 036-903-024E, 037-903-026B, 037-903-026C, 074-903-025J, 074-903-025S
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