Replace Voltage Regulator Without Removing Alternator

PeteB · Post by **PeteB** » 14 Jan 2019, 12:52

Robert says in this video that this is possible and he has done it:
Also note that the brushes are included in the voltage regulator assembly
and these are probably even more common to go bad.

I'm trying to do this on our car and have removed the electrical
connection, one slip on and one 13 mm bolt.
One person who did this removed the dipstick tube and I do think that makes
it a bit easier.
Also removed the 3 med sized Phillips screws. I used a med sized 1/4"
drive Phillips bit in a 1/4 socket with extensions for the first two. The last
one closest to the block I used the socket straight on a 1/4" drive and it
was fairly easy - started it with a small 1/4" ratchet drive.

Now there are 3 plastic tabs that snap on.
The first one on the top snapped off so I have no way to pry up, I'll probably
snap off the rest of this one. The other two are nearly impossible to get
to, especially the one close to the block.

Anyone know of a trick on how to do this, we are almost there to getting
the voltage reg out! Robert?

I watched the video again and it looks like Robert broke them off, the
plastic is so old that it might be the only way. Then there are 3 screws to
hold it on anyway when reinstalling.

Thanks again Robert!

Post by **erikv11** » 14 Jan 2019, 15:04

All I remember is that the hard part was the three screws, the rest was ok. You can't get a bent screwdriver or something under the tabs?

PeteB · Post by **PeteB** » 14 Jan 2019, 15:09

Got the last tab in the back by bending the last .5" of a flat screwdriver and using
it to push the clip. I think the clip broke but at least there are the 3 screws to hold
it in. It cracked as I was prying it off but it has air vents anyway so I don't think it
will matter.

I've done it so far without removing the dip stick but I will probably in order to make putting
it back together easier.

erikv11 - We posted at about the same time, yes that worked.

PeteB · Post by **PeteB** » 15 Jan 2019, 16:43

The two types of Voltage Regulator/Brush Holders for the 100A Bosch alternators are
shown in this thread: viewtopic.php?f=1&t=61610

I need the expensive one Bosch # 1 197 311 520 with the tab, L tab, and
could not find it searching on ebay. Found a link to a cheap copy on ebay on this site:
https://www.ebay.com/itm/REGULATOR-BRUS ... ctupt=true

I really hate to use this cheap copy and am considering buying the incorrect one that
looks to have the same brushes for $18.88 and just transfer the brushes to the original part.

PeteB · Post by **PeteB** » 16 Jan 2019, 14:58

Some say that they can't imagine doing this in the car. You can use a stubby
Phillips screw driver, but this makes all but the rear most cover screw easy:

: VOLVO ALT TOOLS SM.jpg (250.82 KiB) Viewed 9786 times

Here's how I guide it in with one hand:

: VOLVO ALT SCREW SM.jpg (382.34 KiB) Viewed 9786 times

LOB · Post by **LOB** » 16 Jan 2019, 15:06

I've done this operation twice, once removing the alternator (took many hours and blood sweat and tears). And once with the alternator in place using this;

https://www.biltema.se/verktyg/handverk ... 2000020913

Easy peasy, 30 min job done. But remember to remove the dipstick tube!

PeteB · Post by **PeteB** » 16 Jan 2019, 15:21

That is very cool but I used what I had and it was also easy.
Even at 30 deg F out - wear long underwear.
I didn't even remove the dipstick tube.

Post by **Chuck W** » 16 Jan 2019, 17:03

The Bosch PN for the brush set is 1 127 014 028.

PeteB · Post by **PeteB** » 16 Jan 2019, 18:18

I'm trying to confirm that Bosch number for the #1 197 311 520 regulator and
when I google that brush number I came across this Bosch web page where you
can look up "usage in products":
https://www.bosch-automotive-catalog.co ... 1127014028
There's a long list of voltage regulator/brush sets but the #1 197 311 520 is not listed.
I can enter the #1 197 311 520 but it does not break down what brush set is the
correct one. Frustrating, I could not find an exploded parts view for the full alternator
or the #1 197 311 520 part in order to confirm the correct brush set number.
Stumbled onto this website and it seems that the options in a 4mmX6mm brush are
16.5mm long or 18mm long:
https://www.amscovf.com/BRUSHES_c_32973.html
The two that list an OEM bosch number both list 1 127 014 028 that Chuck W provided
so I'm going to order that one, probably from Amazon for $7.43:
https://www.amazon.com/BOSCH-Alternator ... B003NE3EJO

Post by **Chuck W** » 16 Jan 2019, 18:44

They work without issue.