ADJUSTABLE VOLTAGE REGULATORS

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Adjustable Voltage Regulators
for your Volvo (Bosch type alternator)
and many other Bosch Alternators
(VW, Audi, Alfa Romeo, BMW, Porsche and more)
   CLICK HERE FOR INSTALLATION TIPS

Customer Comments: "I finally have appropriate alternator output voltage.  My car has never had enough voltage from its charging system.  I installed your regulator, and was thrilled by the results.  My Autronic SM2 engine management system is much happier.  It idles noticeably better now, and I expect longer battery life as well.   Thank you for an excellent product.  Thank you for your fast service."   R.L., 1984 BMW 633 CSi/Dinan turbo/SM2 "Installed both regulators.  First thing I noticed was that both cockpit voltmeters were off by about a volt or more.  Knowing the voltage at the battery terminals is a great relief.  Both regulators tuned to 14.5 volts and seem to working GREAT.  Thanks for making these fabulous products available."  '79 BMW R100RS motorcycle and '84 BMW 663CSi,  J.M., Jacksonville, FL. "I wish I would have found this adjustable voltage regulator when I first got my 142 3 years ago...It is awsome!!!  I guess I didn't know how bad I needed it until I fried another alternator!!!   Your site is on my favorites now, thanks for the good communication and quick shipping!!!  Volvo 142, C.B., Denver, CO.

ALL ITEMS IN STOCK
All parts are new.  None are refurbished.
 

(Please read WARNINGS regarding installation. Click Here)

Ordering: External Adjustable Regulator Kit (3 pieces) Price: $48.00 plus shipping Order Quantity:   After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will not add automatically. A 20% discount applies on orders of TWO or more kits (i.e.: two for $38.40 each plus shipping) Your discount will be computed upon check-out. Need a Replacement Brush Assembly for the above kit? Price: $16.00 plus shipping Order Quantity: 20% discount applies on orders of TWO or more or these. Shipping for External Regulator Kit or Parts Please Select Shipping and click "Add to Cart"                            USA Shipping: USA Shipping Options Priority Mail $6.00          Shipping to CANADA: Canada Shipping Options Priority Canada $19.00 Other International Shipping: Int'l Shipping Options Global Priority Mail Int'l $30.00                                              To View Cart or Check Out please click below: Shipping cost is the same for one or multiple items. U.S.A. shipping: $6.00 for Priority Mail insured. Canada shipping: International Priority Mail insured: $19.00 (estimated delivery in 5 to 10 days) International Shipping (all other countries):  International Priority Mail insured: $30.00 (5 to 10 days)

 
External Voltage Regulator (regulator only): This adjustable external regulator is the same one included in the above kit, but is available separately.  For those of you with 1980 and older Volvos that came originally equipped with a remote external regulator type setup, this is a direct plug-in item.  This is a new part, not remanufactured.  

This regulator corresponds to the following Volvo Part Numbers:

Ordering: External Adjustable Regulator Only (no harness or brush assembly) In Stock Price: $32.00 plus shipping Order Quantity: After clicking "Add to Cart" above, please select your preferred Shipping below. 20% discount applies on orders of TWO or more (i.e.: two for $25.60 each plus shipping) Your discount will be computed upon check-out. Shipping for External Regulator Please Select Shipping for this Item and click "Add to Cart"                             USA Shipping: USA Shipping Options Priority Mail $6.00          Shipping to CANADA: Canada Shipping Options Priority Canada $19.00 Other International Shipping: Int'l Shipping Options Global Priority Mail Int'l $30.00                                              To View Cart or Check Out please click below: Shipping cost is the same for one or multiple items. U.S. shipping: $6.00 for Priority Mail insured. Canada shipping: International Priority Mail (insured): $19.00 (estimated delivery in 5 to 10 days) International Shipping (all other countries):  International Priority Mail insured: $30.00 (5 to 10 days)

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 Internal Adjustable Voltage Regulator:  In Stock
This complete regulator/brush assembly can be installed in your alternator in place of your original Bosch-type non-adjustable one.  It's an all-in-one part and can be adjusted to approximately 15 volts (I recommend a limit of 14.5).  This style seems to be preferred in the Volvo 740/760 or 940/960 series cars where the alternator is mounted high in the engine bay and the back of the alternator is more easily accessible for adjustment.  This regulator will work in a 240 also, but access to the adjustment screw might be obstructed as mentioned above.   

Adjustment is done with a small screwdriver in the hole you see in the back of the regulator; Clockwise to increase voltage, counter-clockwise to decrease voltage.

(Please read WARNINGS below regarding installation.  Click here)

Ordering: Internal Adjustable Regulator:   In Stock Available in 28 mm or 32 mm type.  The most common is the 28 mm. Price: $32.00 plus shipping Order Quantity: 28 mm Type 32 mm Type After clicking "Add to Cart" above, please select your preferred Shipping below. A 20% discount applies on orders of TWO or more (i.e.: two for $25.60 each plus shipping) Your discount will be computed upon check-out. Shipping for Internal Regulator Please Select Shipping for this Item and click "Add to Cart"                             USA Shipping: USA Shipping Options Priority Mail $6.00          Shipping to CANADA: Canada Shipping Options Priority Canada $19.00 Other International Shipping: Int'l Shipping Options Global Priority Mail Int'l $30.00                                              To View Cart or Check Out please click below: Shipping cost is the same for one or multiple items. U.S. shipping: $6.00 for Priority Mail insured. Canada shipping: International Priority Mail (insured): $19.00 (estimated delivery in 5 to 10 days) International Shipping (all other countries):  International Priority Mail insured: $30.00 (5 to 10 days)

Purchasing Info You may use the cool new Shopping Cart Method above or the Old Fashioned Method below... I accept payment by Credit Card, Money Order or  on-line payment through Paypal, which also accepts major credit cards. >> Ordering Info and Policies Page << To make a simple PayPal payment, please click the PayPal button below... (if the shipping amount indicates $0.00, please add it to your total) For secure VISA or MASTERCARD payment, please click here: >>Dave's Volvo Page Credit Card Entry Form<< Thanks,  Dave Barton EMAIL ME S H I P P I N G   C O S T S U.S. shipping: $6.00 for Priority Mail insured. Canada shipping: Priority Mail International insured: $19.00 USD (estimated delivery: 3 to 5 days), All Other International Shipping:  Priority Mail International insured: $30.00 (5 to 10 days)

I have been using the External Adjustable Regulator Kit in my 1984 245 Turbo for several years and I am very happy with it.  Prior to installing it, I was noticing my OEM Bosch alternator was lucky to put out 12.5 to 12.8 volts with no load.  At times, voltage would drop below 12 volts when under load, such as using headlights, heater fan, etc.   I was shocked to discover how much load was generated with my headlights on (higher wattage bulbs), an electric cooling fan running, and a air conditioning or heater fan going.  Voltage frequently dropped so low that my Rockford Fosgate stereo amplifier would cut out.  If you don't have a good voltage gauge in your car, you might be surprised too at what your car is doing.

Different cars can have different levels of improvement according to the state of your charging system.  My car was a good test for this regulator and the improvement was dramatic to say the least.  Your own results may vary depending on the state of your charging system.

Customer Comment:
"Just wanted to thank you for the regulator and let you know it's working very well.  I'm quite impressed with how well made it is, and how easily the voltage is adjusted.  The dashpot is very smooth and linear in how it varies the voltage."

Frequent Question:
Will an adjustable regulator make my alternator hold voltage at 14.2 volts like I want it to?  My alternator output seems to drop at times, expecially with several things on, like high-beams and air conditioning.

Answer: An adjustable regulator will raise your voltage set-point.  A stock Bosch regulator usually has a set-point at 14.2v, but can drop considerably under heavy load.  An alternator that has a small amp rating (such as 55 amps) will not hold the voltage set-point as well as one with 70, 80, 100 amps or higher.  So the answer is that it might still drop.  The benefit will be your ability to adjust for these loads to some degree.  For example, my '84 242 turbo has the original 55 amp alternator.  The stock regulator usually had an output of about 13.8v with no accessories on. It would dip to below 12v with A/C or other things running.  With the adjustable regulator, I was able to set it for 14.5v.  It still drops some when my high-wattage headlights go to high-beam or when my A/C and auxiliary fan come on, but the drop is acceptable now.  A larger alternator from a later car with 80 or 100 amp capacity would fix this.

The first order of business: disconnect the negative side of your battery.   You will be playing near the big red 12 volt positive cable on the rear of your alternator.

For BEST access to the rear of the alternator in a 240, you should pull the alternator out.  If you have a 700 series, the alternator is up high and access to the back is pretty good.  If you are not confident in your abilities with this type of installation, I recommend you have someone with experience help.  It is easy to permanently damage the regulator (see below damage pic) when installing if you don't know what you're doing.  The brushes are fragile and will BREAK if forced.  But if this happens, the brushes are replaceable.

In the photo to the right, you can see the old internal voltage regulator attached to the back of the alternator.  It's the black box thing (also below left photo).  It's attached by two screws (sometimes slotted, sometimes Phillips)... a very simple removal... no wires to disconnect.  If you are working on a 240 Turbo, you will definitely need to remove the alternator, since it will be impossible to get in behind it while still mounted in place.

Here's a photo of the internal regulator I removed.  It looks like an aftermarket  type.   This 1980 DL (as did many early Volvos) was originally equipped with a factory Bosch external voltage regulator very similar to the one being installed now, except that it was not adjustable.  Somewhere along its life, a previous owner must have "modernized" the car and installed this internal one.
 

Ok, here's the new brush assembly, ready to install in your alternator in place of your internal regulator.  Don't forget to remove the pin on the brush assembly before installation so the brushes will extend as needed.  The pin is only there for shipping.   NOTE: During these procedures it is best not to handle the brushes with your bare hands as the oil from your skin can contaminate them and reduce their life.
 
 
 
 
  

Now the new brush assembly is installed in the alternator.  I have securely mounted the external adjustable regulator (the silver metal box near the radiator fan). You can also see the harness connecting the two components. It really couldn't be much simpler unless I came over and installed it for you. The regulator can be mounted anywhere under your hood within the 32 inch reach of the harness (or elsewhere if you opt for a longer harness).

Total installation time for me was about 45 minutes, but a first-timer might be longer.

After reconnecting the battery, I started the car and checked the voltage (measuring at the battery).  The preset voltage for this regulator seemed to be around 14 volts.  I like it a little higher, so I used a small screwdriver to turn the voltage up to 14.5 volts without any accessories on (such as heater fan, headlights, A/C).  The little screw needs to be turned clockwise just a little bit.  Don't over-do it as the screw is very sensitive. Also, do not try to force the screw past its limit as you will damage the regulator. 

IMPORTANT:  I do not recommend adjusting this regulator without knowing the voltage.  You should use a voltage meter hooked up at the battery to see what you are setting it at.  And please don't rely on your in-dash voltage meter, unless you have verified its accuracy.  Very few I have seen are accurate.  Do yourself a favor and buy an inexpensive digital meter to accurately measure your voltage at the battery.

CUSTOMER INSTALLATION NOTES:
From Zack P.
"My recent (external) adjustable voltage regulator installation went really well. Thanks for making such a nice product. I thought you might be interested to see a clean and simple installation of the remote adjuster. Please see the attached photos. It turns out that the 240's cage/bracket that secures the windshield washer fluid tank has a perfectly good spot for mounting the adjuster bracket; in fact, one of the necessary mounting holes was already there. I removed the washer tank to gain access and space so I could drill the other bolt hole, and then I used two flush/recessed blind nuts to secure the mounting bolts from the back-side and it worked out perfectly. It kind of even looks stock!  Just thought I'd share, since it worked out so well...  Thanks again."


FAILURE TO CHARGE:

Here's a photo of the Internal Adjustable Voltage Regulator in a typical Bosch IR/EF (Internal Regulator/External Fan) alternator from a 740 GLE.  Installation is much easier if the alternator is removed.  The adjusting screw can be seen in the back of this internal regulator.
 
 
 
 
 
 
 
 
 
 
 

WARNING: Doing Your Own Installation? Electrical Parts such as these special regulators are delicate and do not hold up well to abuse.  If you are not experienced with this sort of installation, then I STRONGLY recommend you have a professional or someone with experience install it for you.  Otherwise, if you force the crud out of it and destroy it, please don't write me and tell me it simply "fell apart" on its own like this customer did. Please put your claw hammers away before installing one of these.

ALTERNATOR TESTING
If you are using an external regulator with a separate brush assembly, the below Full Field Test method will be pretty easy to do.  It will determine how well your alternator is charging.  In case of a problem, this procedure can help you decide if the alternator is at fault or if the regulator is at fault. This test is standard procedure in older shop manuals.

Basically, you'll be bypassing the regulator, so a full 12V is applied to the alternator rotor winding. The battery voltage should go to about 16V, so you should only run the engine just long enough to measure the voltage.

On the wire harness I supply with the External Kit, the wire colors are: D- (BLACK), D+ (RED), DF (GREEN), which will be for Ground, Posative, and Field.  The bypass is applied by unplugging the regulator harness at the regulator end and jumpering the D+ (RED) and DF (GREEN) socket pins.   The remaining D- (BLACK) pin is already grounded to the alternator case as it should be.

If you get around 16V or more, the alternator is good and the problem is likely the regulator or other wiring in the car.

The same test can be done with an internal type regulator setup by replacing the brush/regulator assembly with one that has been modified (regulator portion removed) with an internal jumper between the D+ and DF pins. This could be made from an old bad internal regulator unit. Just make sure the brushes are still in good shape. 

A good Brickboard discussion on Alternator Wear and Slip Rings:
http://www.brickboard.com/RWD/index.htm?id=725699

ALTERNATIVE MODS TO EXISTING REGULATORS
http://articles.mbz.org/electric/regulator/

OTHER LINKS
But what if I think my alternator is bad?
You might check out the following for tips on diagnosing a bad alternator....
http://www.misterfixit.com/alterntr.htm
http://www.humanspeakers.com/audi/alternator.htm
 

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