Volvo Adjustable Voltage Regulators

ADJUSTABLE VOLTAGE REGULATORS

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Web	www.davebarton.com

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 parts are new. None are refurbished.

External Adjustable Regulator. Complete Kit.
This kit incorporates three pieces: a separate brush assembly will replace your existing internal voltage regulator in the rear of your alternator, plus a remote ADJUSTABLE regulator is used, which may be mounted on a fender or other convenient place (It's always preferable to mount it away from energy-robbing engine heat), and a 32 Inch (81 cm) connecting harness.

This regulator is adjustable to approximately 15 volts (although I recommend a limit of about 14.5v). The harness I offer is covered with high quality black poly-vinyl (which matches the original black harness covering Volvo used), not the cheap plastic split-loom cover supplied with similar kits I have seen. This is custom and available only from me.

The voltage adjustment is done with a small flat screwdriver on the under side of the regulator (see photo);
Clockwise to increase voltage; Counter-clockwise to decrease voltage.

This external style of regulator works very well with the Volvo 240/260 series cars (especially 240 Turbos) where the alternator is low in the engine bay and on the exhaust side of the engine. Access to the back of the alternator for adjustments can be difficult (impossible with a 240 Turbo). Also on a 240, the very hot exhaust manifold and turbo is very close to the alternator. By putting a remote regulator a distance away from this heat source, you will see more consistent voltage. Scroll down to the installation tips to see how I installed this kit in one of my own 240 models.

(Please read WARNINGS regarding installation. Click Here)

CUSTOM LENGTH HARNESS: If a standard 32 inch harness is not long enough for your installation, I can supply a custom harness of any length for a small additional fee. You may choose a harness with finished connector ends or with one or both ends unassembled. This will permit you to trim it to your preferred length and then assemble the final connector end(s) yourself. Please email for more information.

This item will fit all Volvo 240/260 '75-'93, 740/760 '84-'92, 940/960 '91-'95 with Bosch external fan alternator.

I have found that these regulators will also fit MANY other Bosch external fan alternators (non-Volvo). This particular type fits those with 28mm slip rings (A rare 32mm slip ring type is also available in an Internal Regulator type). Most older Volvos use 28mm slip rings. There are 28mm slip ring types found in many Saabs, VW's, Audis and others too.

Scroll down for Part Number Cross-References or email Dave.

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ORDER HERE. External Adjustable Regulator Kit. IN STOCK
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 in the cart upon check-out.

Price: $48.00 plus shipping
Order Quantity (USA shipping only):
After clicking "Add to Cart" above, please select your preferred Shipping below.
Shipping will not add automatically.

Shipping for External Regulator Kit or Parts. Please Select Shipping and click "Add to Cart"
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RELATED ITEM: 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 too.

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)
                                   First Class Mail Canada (NOT INSURED): $4.00 (delivery is slower)
International Shipping (all other countries): International Priority Mail insured: $30.00 (5 to 10 days)
                                                                                   First Class Mail (NOT INSURED): $7.00 (delivery is slower)

Shipping for Non-Insured or Under-Insured Shipments
All First Class Mail shipments are NOT INSURED and DO NOT HAVE TRACKING.
If you choose to ship your order using First Class Mail, it will not have insurance or tracking.
Please remember that if your order becomes LOST in the mail, I will not be responsible to send you another order for free.
It is VERY rare that a mail loss occurs with my orders (less than 1%), but the possibility exists.

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 (and many other European cars) 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:

214 719	1 234 519	1 308 030	241 534
241 808	241 960	246 585	530165
530 878	531 914	588 950

This regulator corresponds to the following Bosch Part Numbers:

0 190 062 001	0 190 062 002	0 190 062 004	0 190 062 005
0 190 062 007	0 190 600 001	0 190 600 004	0 190 600 005
0 190 600 006	0 190 600 008	0 190 600 009	0 190 600 010
0 190 600 011	0 190 600 012	0 190 600 013	0 190 600 014
0 190 600 016	0 190 600 018	0 190 600 020	0 190 600 021
0 190 601 001	0 190 601 002	0 190 601 003	0 190 601 006
0 190 601 007	0 190 601 008	0 190 601 009	0 190 601 010
0 190 601 011	0 190 601 012	0 190 601 013	0 190 601 017
0 192 062 001	0 192 062 004	0 192 062 005	0 192 062 007
9 190 085 001	9 190 087 011

(Please read WARNINGS regarding installation. Click Here)

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Ordering: External Adjustable Regulator Only. In Stock.
20% discount applies on orders of TWO or more (i.e.: two for $25.60 each plus shipping)
Your discount will be computed in the cart upon check-out.

Price: $32.00 plus shipping
Order Quantity:
After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will not add automatically.

Shipping for External Regulator. Please Select Shipping for this Item and click "Add to Cart"
                            USA Shipping:
Shipping to CANADA:
Other International Shipping:
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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)
                                   First Class Mail Canada (NOT INSURED): $4.00 (delivery is slower)
International Shipping (all other countries): International Priority Mail Insured: $30.00 (5 to 10 days)
                                                                                   First Class Mail (NOT INSURED): $4.00 (delivery is slower)

Shipping for Non-Insured or Under-Insured Shipments
All First Class Mail shipments are NOT INSURED and DO NOT HAVE TRACKING.
If you choose to ship your order using First Class Mail, it will not have insurance or tracking.
Please remember that if your order becomes LOST in the mail, I will not be responsible to send you another order for free.
It is VERY rare that a mail loss occurs with my orders (less than 1%), but the possibility exists.

*************************************************************************

Internal Adjustable Voltage Regulator
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 regarding installation. Click here)

This item will fit all Volvo 240/260 '75-'93, 740/760 '84-'92, 940/960 '91-'95 with Bosch external fan alternator.

Scroll down for Part Number Cross-References or email Dave.

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Ordering: Internal Adjustable Regulator: In Stock
Available in 28 mm or 32 mm type. The most common is the 28 mm.
A 20% discount applies on orders of TWO or more (i.e.: two for $25.60 each plus shipping)
Your discount will be computed in the cart upon check-out.

Price: $32.00 plus shipping
Order Quantity:
After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will not add automatically.

Shipping for Internal Regulator. Please Select Shipping for this Item and click "Add to Cart"
                            USA Shipping:
Shipping to CANADA:
Other International Shipping:
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)
                                   First Class Mail Canada (NOT INSURED): $4.00 (delivery is slower)
International Shipping (all other countries): International Priority Mail Insured: $30.00 (5 to 10 days)
                                                                                   First Class Mail (NOT INSURED): $4.00 (delivery is slower)

Shipping for Non-Insured or Under-Insured Shipments
All First Class Mail shipments are NOT INSURED and DO NOT HAVE TRACKING.
If you choose to ship your order using First Class Mail, it will not have insurance or tracking.
Please remember that if your order becomes LOST in the mail, I will not be responsible to send you another order for free.
It is VERY rare that a mail loss occurs with my orders (less than 1%), but the possibility exists.

**********************************************************

Internal Voltage Regulator, non-adjustable, 14.5 volts
This internal regulator can be installed in your alternator in place of your original Bosch-type non-adjustable one.
Factory set for 14.5 volts (standard regulators are set at 14.1 volts).

(Please read WARNINGS regarding installation. Click here)

This item will fit all Volvo 240/260 '75-'93, 740/760 '84-'92, 940/960 '91-'95 with Bosch external fan alternator.

I have found that these regulators will also fit MANY other Bosch external fan alternators (non-Volvo). This particular type fits those with 28mm slip rings. There are 28mm slip ring types found in many Saabs, VW's, Audis and others too.

Scroll down for Part Number Cross-References or email Dave.

ORDER HERE: Internal Regulator
non-adjustable 14.5 Volt,   IN STOCK
If all you need is a stock replacement. 28 mm type only.
These are factory set for 14.5 volts (higher than the standard 14.1 volt type).
A 20% discount applies on orders of TWO or more (i.e.: two for $19.20 each plus shipping)
Your discount will be computed in the cart upon check-out.

Price: $24.00 plus shipping
Order Quantity:
After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will not add automatically.

Shipping for Internal Regulator. Please Select Shipping for this Item and click "Add to Cart"
                            USA Shipping:
Shipping to CANADA:
Other International Shipping:
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)
                                   First Class Mail Canada (NOT INSURED): $4.00 (delivery is slower)
International Shipping (all other countries): International Priority Mail Insured: $30.00 (5 to 10 days)
                                                                                   First Class Mail (NOT INSURED): $4.00 (delivery is slower)

Shipping for Non-Insured or Under-Insured Shipments
All First Class Mail shipments are NOT INSURED and DO NOT HAVE TRACKING.
If you choose to ship your order using First Class Mail, it will not have insurance or tracking.
Please remember that if your order becomes LOST in the mail, I will not be responsible to send you another order for free.
It is VERY rare that a mail loss occurs with my orders (less than 1%), but the possibility exists.

**************************************************
NEW ITEM
SPECIAL REGULATORS:

Occasionally I get special requests for adjustable regulators than can handle larger loads. The two regulators below might be of interest to you. These are compatible with any Bosch EF/IR alternator using a 28 mm slip ring (same as above kits).
F540HDA (Heavy Duty Adjustable)
or F540XHDA (Extra Heavy Duty Adjustable).
The F540HDA is the adjustable version of the standard Ford type voltage regulator. Short circuit protected. Load dump protected.
The F540XHDA is also built with dual 8 amp power transistors and extra heat sinking to help keep it cooler under heavy loads. Short circuit protected. Load dump protected. And adjustable to 15 plus volts.

The voltage adjustment is done by this trimpot found under the cover.

However, I have customized these regulators with an access hole and soft plug to make adjusting much easier. There is no longer a need to remove the cover.
Adjustment: Clockwise to increase voltage, counter-clockwise to decrease voltage. Turn slowly in small increments when checking.

Each full kit will come with the following:
1. F540HDA or F540XHDA customized for external adjustment.
2. 32 inch wire harness.
3. Alternator brush holder (28 mm type).
4. Full Instructions.

CUSTOM LENGTH HARNESS: If a standard 32 inch harness is not long enough for your installation, I can supply a custom harness of any length for a small additional fee. You may choose a harness with finished connector ends or with one or both ends unassembled. This will permit you to trim it to your preferred length and then assemble the final connector end(s) yourself. Please email for more information.

Ordering: F540HDA (Adjustable) Full Kit. In Stock
20% discount applies on orders of TWO or more (i.e.: two for $43.20 each plus shipping)
Your discount will be computed in the cart upon check-out.
Price: $54.00 plus shipping
Order Quantity: After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will not add automatically.

Ordering: F540XHDA (Extra Heavy Duty Adjustable) Full Kit. In Stock
20% discount applies on orders of TWO or more (i.e.: two for $48.00 each plus shipping)
Your discount will be computed in the cart upon check-out.
Price: $60.00 plus shipping
Order Quantity: After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will not add automatically.

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)
                                   First Class Mail Canada (NOT INSURED): $4.00 (delivery is slower)
International Shipping (all other countries): International Priority Mail Insured: $30.00 (5 to 10 days)
                                                                                   First Class Mail (NOT INSURED): $4.00 (delivery is slower)

Shipping for Non-Insured or Under-Insured Shipments
All First Class Mail shipments are NOT INSURED and DO NOT HAVE TRACKING.
If you choose to ship your order using First Class Mail, it will not have insurance or tracking.
Please remember that if your order becomes LOST in the mail, I will not be responsible to send you another order for free.
It is VERY rare that a mail loss occurs with my orders (less than 1%), but the possibility exists.

*******************************************************************

REGULATOR ONLY
F540HDA (Heavy Duty Adjustable)
or F540XHDA (Extra Heavy Duty Adjustable).
The F540HDA is the adjustable version of the standard Ford type voltage regulator. Short circuit protected. Load dump protected.
The F540XHDA is also built with dual 8 amp power transistors and extra heat sinking to help keep it cooler under heavy loads. Short circuit protected. Load dump protected. And adjustable to 15 plus volts.

These are compatible with any Ford vehicle using the F540 type external regulator.

Ordering: F540HDA (Regulator Only). In Stock
20% discount applies on orders of TWO or more (i.e.: two for $28.80 each plus shipping)
Your discount will be computed in the cart upon check-out.
Price: $36.00 plus shipping
Order Quantity: After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will not add automatically.

Ordering: F540XHDA (Regulator Only). In Stock
20% discount applies on orders of TWO or more (i.e.: two for $33.60 each plus shipping)
Your discount will be computed in the cart upon check-out.
Price: $42.00 plus shipping
Order Quantity: After clicking "Add to Cart" above, please select your preferred Shipping below. Shipping will not add automatically.

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)
                                   First Class Mail Canada (NOT INSURED): $4.00 (delivery is slower)
International Shipping (all other countries): International Priority Mail Insured: $30.00 (5 to 10 days)
                                                                                   First Class Mail (NOT INSURED): $4.00 (delivery is slower)

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S H I P P I N G C O S T S
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All Other International Shipping: Priority Mail International insured: $30.00 (5 to 10 days)

Bosch Alternator -- External Fan with Internal Regulator 28mm Slip Ring

The 28mm External or Internal Adjustable Regulators on this page will exchange correctly with all these Bosch-type Voltage Regulator Part Numbers and Bosch Alternator Part Numbers.
If you have a regulator part number that does not correspond, feel free to ask.

Alfa-Romeo 116100506011, 119130506000, 119130506023, 705684800000, Alfa Romeo 164 '91-'92, Milano '88 using Bosch 0-120-488-102 28mm alternator, Milano '89, Spider '90-'94 using Bosch 0-120-488-102 or 0-120-488-103 28mm alternator,
Audi 4000 84-87 1800cc, 4000 85-87 2200cc 5 Cyl, 5000 85-86 2000cc Diesel Turbo, 5000 84-86 2200cc 5 Cyl, 5000 Turbo 86-88 2226cc 5 Cyl, 5000 Turbo 86-88 2309cc 5 Cyl, 5000 Turbo Quattro 84-88 2226cc 5 Cyl, 5000 Turbo Quattro 86-88 2309cc 5 Cyl, 80/90 88-91 2000cc, Coupe 83-87 All 5 Cyl eng., Quattro 85-88 All 5 Cyl eng.: AL27X, AL33X, 025 903 023E, 026 903 015B, 034 903 015D, 034 903 803, 026 903 015F, 026 903 017, 026 903 017B, 026 903 017BX, 026 903 017X, 026 903 023, 034 903 015K, 034 903 015M, 034 903 016C, 035 903 017A, 035 903 017AU, 035 903 017AV, 035 903 017AX, 035 903 023B, 035 903 023D, 049 903 023P, 049 903 027, 049 903 027A, 049 903 027X, 068 903 017B, 068 903 017BX, 068 903 017P, 068 903 017PX, 068 903 018A, 068 903 018B, 068 903 029M, 068-903-803, 068 903 803D, 069 903 017A, 069 903 017AX, 069 903 023D, 069 903 023G, 069 903 023H, 176 903 027.
BMW 1711391, 1231-1726002, 1231-1279548, 1232-1711399, 1232-1271644, 1231-1271664, 320i '77-'83 with Bosch 0-120-489-039 and 0-120-489-040 alternator, 318i '84-'85 and '91-'92 with Bosch 0-120-469-617, 0-120-469-918 and 0-120-469-919 alternator, 325e '84-'88 with Bosch 0-120-469-617 or 0-120-469-779 alternator, 325i '87-'93 with Bosch 0-120-469-779, 0-120-469-985, or 0-120-468-105 alternator (not '92-'95 with Bosch 0-120-465-031 or 0-120-485-048 14mm alternator), 525i '89-'91 with Bosch 0-120-468-042, 0-120-468-043, 0-120-469-869, 0-120-469-912, 0-120-468-062 (opt 115A '91-'92), 0-120-468-064 (opt 140A '91-'92) alternator (not '92-'95 with Bosch 0-120-465-031 or 0-120-485-048 14mm alternator), 528e '82-'88 with Bosch 0-120-489-031, 0-120-469-617 and 0-120-469-778 alternator, 528i '79-'81 with Bosch 0-120-489-037 alternator, 530i '75 with Bosch 0-120-400-771 alternator, 535i '85-'93 with Bosch 0-120-468-007, 0-120-468-008, 0-120-469-775, 0-120-469-776, 0-120-468-096, 0-120-468-098 alternator, 633 CSi '78-'81 with Bosch 0-120-489-037 alternator (lacking info on later 633 and 635 CSi), 733i '78-'81 with Bosch 0-120-489-037 alternator (lacking info on later 733 and early 735), 735i '87-'92 with Bosch 0-120-468-007, 0-120-468-008, 0-120-468-013, 0-120-469-775, 0-120-469-776, 0-120-468-096 and 0-120-468-098 alternator, 750i '88-'94 with Bosch 0-120-468-030, 0-120-468-033 and 0-120-339-547 alternator, 850 Ci/CSi '93-'95 with Bosch 0-120-468-033, 0-120-339-547 alternator,
M3 E30 '87-'91 with Bosch 0-120-469-804, 0-120-469-805 alternator, M5 E28 '87-'88 (it will fit, but I'm lacking specific PNs), (lacking info on '89- '90 M5), M5 E34 '91-'93 with Bosch 0-120-468-073, 0-120-468-074, 0-120-468-050, 0-120-468-051 and 0-120-468-067 alternator.
Bosch AL30X, AL32X, AL33X, AL54X, AL57X, AL58X, AL140X, AL173X,
0-120-468-001, 0-120-468-002, 0-120-468-003, 0-120-468-006, 0-120-468-070; 0-120-469-002, 0-120-469-003, 0-120-469-012, 0-120-469-015, 0-120-469-541, 0-120-469-542, 0-120-469-545, 0-120-469-546, 0-120-469-551, 0-120-469-552, 0-120-469-553, 0-120-469-554, 0-120-469-556, 0-120-469-558, 0-120-469-559, 0-120-469-560, 0-120-469-561, 0-120-469-563, 0-120-469-564, 0-120-469-566, 0-120-469-575, 0-120-469-576, 0-120-469-577, 0-120-469-578, 0-120-469-581, 0-120-469-582, 0-120-469-586, 0-120-469-587, 0-120-469-593, 0-120-469-594, 0-120-469-595, 0-120-469-598, 0-120-469-599, 0-120-469-600, 0-120-469-602, 0-120-469-603, 0-120-469-604, 0-120-469-605, 0-120-469-606, 0-120-469-607, 0-120-469-610, 0-120-469-617, 0-120-469-618, 0-120-469-619, 0-120-469-621, 0-120-469-622, 0-120-469-623, 0-120-469-624, 0-120-469-631, 0-120-469-632, 0-120-469-633, 0-120-469-635, 0-120-469-636, 0-120-469-637, 0-120-469-638, 0-120-469-639, 0-120-469-640, 0-120-469-648, 0-120-469-649, 0-120-469-650, 0-120-469-651, 0-120-469-654, 0-120-469-666, 0-120-469-670, 0-120-469-674, 0-120-469-675, 0-120-469-677, 0-120-469-680, 0-120-469-689, 0-120-469-690, 0-120-469-696, 0-120-469-697, 0-120-469-698, 0-120-469-699, 0-120-469-700, 0-120-469-701, 0-120-469-702, 0-120-469-703, 0-120-469-704, 0-120-469-705, 0-120-469-706, 0-120-469-707, 0-120-469-708, 0-120-469-710, 0-120-469-711, 0-120-469-712, 0-120-469-714, 0-120-469-715, 0-120-469-716, 0-120-469-717, 0-120-469-718, 0-120-469-719, 0-120-469-720, 0-120-469-721, 0-120-469-727, 0-120-469-728, 0-120-469-729, 0-120-469-732, 0-120-469-733, 0-120-469-734, 0-120-469-735, 0-120-469-737, 0-120-469-739, 0-120-469-740, 0-120-469-741, 0-120-469-742, 0-120-469-743, 0-120-469-754, 0-120-469-757, 0-120-469-758, 0-120-469-759, 0-120-469-768, 0-120-469-775, 0-120-469-776, 0-120-469-778, 0-120-469-780, 0-120-469-782, 0-120-469-783, 0 120 469 784, 0 120 469 786, 0 120 469 787, 0-120-469-790, 0 120 469 793, 0-120-469-794, 0-120-469-795, 0-120-469-804, 0-120-469-805, 0-120-469-806, 0-120-469-816, 0-120-469-817, 0-120-469-818, 0-120-469-819, 0-120-469-820, 0-120-469-821, 0-120-469-822, 0-120-469-823, 0-120-469-828, 0-120-469-830, -831, -832, -834, -835, -836, -839, -845, -846, -862, -863, -864, -865, -868, -869, -876, -877, -878, -879, -885, -886, -887, -888, -901, -902, -903, -904, -906, -907, -908, -918, -919, -967, -971, -972, -975, 0 120 469 992, 0 120 469 993, 0 120 469 998,
0-120-484-012;
0-120-488-114, -152, -183, -184, -219, -220, -221, -238, -245, -246, -247, -249, -254, -263, -264, -265, -279, -280, -976; 0-120-489-002, -003, -004, -005, -006, -007, -008, -009, -010, -011, -012, -013, -014, -015, -016, -017, -028, -029, -030, -031, -036, -037, -038, -039, -040, -041, -042, -043, -044, -045, -046, -057, -058, -062, -063, -076, -077, -080, -081, -082, -083, -093, -094, -107, -108, -109, -110, -111, -112, -113, -114, -115, -116, -117, -120, -121, -122, -128, -129, -130, -131, -133, -134, -137, -138, -139, -141, -142, -143, -144, -152, -153, -154, -167, -170, -171, -186, -191, -195, -196, -197, -198, -199, -200, -201, -202, -203, -204, -205, -206, -207, -208, -209, -210, -211, -215, -217, -218, -220, -228, -229, -235, -236, -237, -238, -239, -246, -247, -248, -249, -250, -260, -261, -262, -282, -283, -308, -338, -349, -351, -352, -353, -365, -366, -367, -368, -369, -370, -371, -372, -373, -380, -381, -385, -386, -401, -403, -418, -419, -420, -421, -422, -423, -432, -433, -434, -436, -437, -438, -474, -486, -487, -489, -493, -494, -549, -903, -904, -909, -91, -910, -960, -961, -963, -964, -965, -966, -967, -968, -969, -976, -980, -981, -982, -983, -986, -987, -988, -990, -991, -992, 0-120-488-993;
0-120-489-362, 0-120-489-364, 0-120-489-365, 0-120-489-369, 0 120 489 069, 0 120 489 070, 0 120 489 183, 0 120 489 286, 0 120 489 296,
0-886-031-501,
1-192-052-015, 1-192-052-016, 1-192-052-020, 1-192-052-021, 1-192-052-024, 1-192-052-025, 1-192-052-027, 1-192-05-029,
1-197-311-003, 1-197-311-004, 1-197-311-005, 1-197-311-006, 1-197-311-007, 1-197-311-008, 1-197-311-009, 1-197-311-010, 1-197-311-011, 1-197-311-012, 1-197-311-013, 1-197-311-018, 1-197-311-021, 1-197-311-022, 1-197-311-023, 1-197-311-026, 1-197-311-027, 1-197-311-028, 1-197-311-035, 1-197-311-038, 1-197-311-039, 1-197-311-040, 1-197-311-050, 1-197-311-090, 1-197-311-800,
9-120-080-129, 9-120-143-036; 9-120-144-205, -206, -207, -216, -217, -237, -281, -282, -290, -292, -301, -305, -600, -601, -602, -603, -604, -608, -609, -612, -615, -616, -619, -620; 9-120-334-324,
9 127 041 109, 9 127 041 110, 9 127 041 200
9-191-337-303,
Deutz-Allis 93155548
Fendt X830060022010
Ford 86GB-10316AA, 82BB-10316-AA, E5RD-10316-BA
Fiat 60751135, 60751403, 60751439, 9938171, 9942848, 9942885, 99428884, 9950155, 9960176, Fiat 128 '72-'74 using Bosch 0-120-300-559 or 0-120-300-568 28mm alternator, X1/9 '74 using Bosch 0-120-300-559 or 0-120-300-568 28mm alternator, Bertone '83-'84 using Bosch 0-120-489-072 28mm alternator,
GM 90349704, 90349907
IHC 1530372C1
KHD 81211111
Lancia Beta '74 using Bosch 0-120-300-559 or 0-120-300-568 28mm alternator,
Lucas 21221349, UCB403
Mercedes Benz 002-154-4106, 002-154-5106, 002-154-7206, 002-154-7906
Opel 1204256, 1204259, 1204253, 90007041
Porsche 0 190 601 006, 0 192 052 006, 1 197 311 090 (1976-77 930 with SEV alt - external reg fits), 944 603 14100, 944 603 14101 (1983-91 944), 928-603-142-00 (1992-95 968), 928-603-153-00, (lots of Porsche applications for Bosch internal regulator, external fan alternators). Other Porsche fitments: 1989-98 911 with Bosch alt, 1976 912 with Bosch alt - external reg fits, 1970-76 914 with Bosch alt - external reg fits, 1977-79 924 with Bosch alt, 1986-88 924 with Bosch alt, 1978-82 928 with Bosch alt, 1985-95 928 with Bosch alt,
Saab 8571846, 8590549, Saab 99 '73-'80 with Bosch 0-120-400-922 and 0-120-489-881 alternator (not models with SEV alternator), 900 Turbo and non-turbo '79-'94 with Bosch 0-120-468-067, 0-120-489-881, 0-120-469-683, 0-001-311-108, 0-120-489-253, 0-120-469-611, 0-120-469-682 alternator (not '94 and later with internal fan alternator), 9000 '87-'94 with Bosch 0-120-468-035, 0-120-468-045, 0-120-469-682, 0-120-469-684, 0-120-469-881 alternator,
Volvo 1235887, 1257294-7, 1258994-1, 1269124-2, 1269702-5, 1323351-5, 1323488-5, 1323912-4, 1324142-7, 1324617, 1324957-8, 134850, 1348507-3, 1363493-6, 1363496-9, 1363511-5, 1398327-5, 244332, 269479-2, 269629-0, 5001961-1, 5002730-9,
Volkswagen I get a lot of questions about VW applications. Hopefully this will help.
Cabriolet 84-93 1800cc, Corrado 1800cc 89-92, Fox 87-93 1800cc, Golf 85-92 1800cc, Jetta 83-84 1715cc and 1780cc, Jetta 85-92 1800cc, Golf or Jetta 1600 diesel 85-86, Jetta 1600 diesel 89-92, Passat 1800cc 91-92, Quantum 85-85 1800cc, Scirocco 83-84 1780cc, Scirocco 85-88 1800cc, Vanagon 83-84 1913cc, Vanagon 1913cc 89, Vanagon 86-92 2100cc, AL30X, AL32X, AL173X, 025 903 023D, 025 903 023DX, 026 903 015, 026 903 015A, 026 903 015AX, 026 903 015D, 034 903 803, 37 903 018A, 037 903 023A, 037 903 023P, 068 903 017L, 068 903 017LX, 068 903 017N, 068 903 017NX, 068 903 017Q, 068 903 018, 068 903 018X, 068 903 029C, 068 903 029E, 068 903 029Q, 068 903 029QX, 068 903 033E, 069 903 023F, 068-903-803, 068 903 803D, 176 903 029.

If you have a regulator part number that does not correspond, feel free to ask.

Bosch Alternator -- External Fan with Internal Regulator 32mm Slip Ring

A 32mm Internal Adjustable Regulator is rare. It will not exchange with a 28mm type. These Voltage Regulator Part Numbers are 32mm applications
Alfa Romeo GT V6 '81-'86, Milano '86-'87, Milano '88 using Bosch 0-120-489-716 32mm alternator, Spider '81-'89 using Bosch 0-120-489-716 32mm alternator,
Audi/Volkswagen 028-903-803A, 049-903-803B, 049-903-803E, 049-903-803F, 052-903-803, 059-903-803, 059-903-803B, 059-903-803C, 063-903-803, 070-903-803A
BMW 1231 1286 073, 530i '76-'78 with Bosch 0-120-489-650 32mm alternator, 630 CSi '77 with Bosch 0-120-489-621 32mm alternator,
Bosch 0-192-052-001, 0-192-052-002, 0-192-052-004, 0-192-052-005, 0-192-052-006, 0-192-052-008, 0-192-052-011, 0-192-052-012, 0-192-052-013, 0-192-052-014, 0-192-052-017, 0-192-052-018, 0-192-052-019, 0-192-052-022, 0-192-052-024, 0-192-052-025, 0-192-052-026, 0-192-052-028, 0-192-052-031, 1-197-311-000, 1-197-311-001, 1-197-311-002, 1-197-311-090
Delco 90009353
Fiat 4 474 755, 4 475 296, 4 731 653, 9 927 829, 9 933 186, 9 934 791, 82 302 913, Fiat 124 '76-'78 (and Fiat 131 '78) using Bosch 0-120-489-641 32mm alternator, Brava or Spider '79-'82 using Bosch 0-120-489-823, 0-120-489-824 or 0-120-489-641 32mm alternator, Pininfarina '83-'84 using Bosch 0-120-489-823 or 0-120-489-824 32mm alternator, Strada and X1/9 '81-'82 using Bosch 0-120-489-875 or 0-120-489-943 32mm alternator,
Ford 1477502, 71BB-10316-AA
GM 90009353
Iskra 10-120-110, 11-125-003, 11-125-040, 11-125-049, 11-125-073, 11-125-117, 11-125-121, NRE121301, AER7201, AER1503, AER7207, AER1527
Lancia Beta '75-'82 using Bosch 0-120-489-743 or 0-120-489-877 32mm alternator, Zagato '79-'82 using Bosch 0-120-489-743 or 0-120-489-877 32mm alternator,
Lucas 01221 152, 21221 347, 21221 373, 21931 009, UCB400
Magirus-Deutz 4 248 4638
Magneti-Marelli 648-080-10, 648-080-11, 648-080-12, 648-081-09, RTT110A, RTT110AB, RTT110ABT
Mercedes Benz 002-154-0606, 002-154-1806, 002-154-2506, 002-154-5806
Opel 1204244, 1204252
Porsche 1980-82 924 with Bosch alt, 1983-84 928 with Bosch alt
Valeo 505-055, NB411

Advantages of an Adjustable Voltage Regulator

These adjustable regultators will do wonders for most Volvo 200, 700, or 900 series charging systems. They allow you to set your voltage instead of relying on the preset (usually too low) voltage found in most older cars with Bosch alternators.

Since most alternators typically produce a little less voltage at idle versus cruising, and it's impossible to make outputs consistent depending on precise idle speed, it is strongly recommended that voltage output tests be done with the engine at 1,500 rpm, where voltage output will be more stable.

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 at idle would dip below 12 volts when under a moderate load, such as using headlights and blower fan. I was shocked to discover how much load was generated with my headlights on (I was using higher wattage bulbs), an electric cooling fan running, and with the air conditioning on. Voltage frequently dropped so low that my stereo amplifier would cut out. If you don't have a good voltage (minimum of 12 volts at its lowest), engine control units can be negatively affected too.

Another advantage of using a externally mounted regulator is that the regulator can be place further away from a hot exhaust manifold (like in a Volvo 240). You may have already noticed this; Bosch regulators have a negative temperature coefficient that causes the charge output voltage to drop as the device heats up. So a cooler running regulator means much better efficiency.

After installing this kit in my 245, I set the no-load voltage to 14.5 volts (at 1500 rpm) and I was amazed at the difference. My headlights were brighter, my electric primary cooling fan was running much faster, and my stereo amplifier worked perfectly for the very first time.

Different cars can have different levels of improvement according to the state of your charging system and the amperage rating of your alternator. An 80 or 100 amp alternator will alway perform better under load than a smaller 55 amp type. My car was a good test for this regulator and the improvement was dramatic to say the least. Your own results may vary.

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."

Frequently Asked 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 initial set-point. A stock Bosch regulator usually has a factory set-point at 14.1 to 14.2v. Rarely will you actually see that voltage with a stock regulator. And it will usually drop considerably under load and when hot. An alternator that has a smaller amp rating (such as 55 amps) will not hold a voltage set-point as well as one with 70, 80, 100 amps or higher. So the answer is that it will likely still drop with load and heat. The benefit of setting a higher initial set-point will allow your charging system to handle loads better or even higher loads to some degree. For example, when my '84 242 turbo had 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 the A/C or other high-load things running. With the adjustable regulator, I was able to set it for 14.5v. It still dropped some with my headlights on or when my A/C came on, but the drop became acceptable. A larger alternator from a later car with 80 or 100 amp capacity would improve the drop under load.

Installing an Adjustable Voltage Regulator
(Please read WARNING below regarding installation)

For instruction purposes, I installed a standard External Adjustable Kit in my 1980 242 DL. Before the installation, I checked the no-load voltage at the battery and found it to be 13.7 volts (fairly standard and not too bad for an older Volvo Bosch alternator).

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 when installing if you don't know what you're doing (see damage pic near bottom of page). The brushes are fragile and will BREAK if forced.

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 (external regulator type) ready to install in 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 greasy hands as you can contaminate them and reduce their efficiency and 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 it at the battery). The factory 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. 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 real voltage meter hooked up at the battery to see what you are setting it at. And please don't rely on your in-dash volt gauge, 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.

A MOST EXCELLENT CUSTOMER INSTALLATION REPORT:

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!

After installing a new regulator or brush assemply, an initial FAILURE TO CHARGE can occur on a high-mileage alternator (this usually means well WORN). I have seen this occur several times on my own installations and several customers have experienced it. After installing a new brush assembly, I found that it was not charging right away. It can be quite puzzling and you may begin thinking you have a faulty regulator. A classic symptom is having good battery voltage (maybe 12.3 to 12.6 volts) with the engine OFF, and having LESS voltage at the battery with the engine running. In this situation, turning the adjusting screw will have no effect.

If you have a failure after replacing these parts, the obvious things to check will be your connections at the rear of the alternator.
1. The BIG RED CABLE is the main power cable. It goes to the starter motor and then to the battery.
2. The SMALL RED WIRE completes the Battery Warning Light Circuit (light on your dash) and if it is not connected properly the alternator may not charge. You will know this circuit is complete if you see the Battery Light ON when the ignition key is turned to the 'ON' position with engine still OFF.
3. There is a GROUND cable that is attached to the alternator case (usually a small stud with an 8 mm head nut). The other end will be connected to the engine or alternator bracket. If this ground is not complete, the alternator will definitely not charge.

Also, if you have an external regulator, check the 3-pole connections at the brush assembley and at the regulator. It is possible that one of the wire terminal inserts in the plug became dislodged when the plug was pushed on. It happens.

If the above connections are good, and still you aren't charging, it is possible there is a less than optimum contact between the NEW brushes and your OLD alternator slip rings. When I first discovered this I was quite puzzled, but as it turned out the friction end of the brushes just needed some time to wear in to establish good electrical connections with the slip rings. So it would seem one cure would be to continue running the engine until the voltage regulator starts working... the theory being that once a good electrical connnection is established the voltage should come up. This has worked for some customers.

Here's the experience of one customer:
"I took the new brushes out when there was no charge and noticed the contact spot was real small. It is possible that they need to take the shape of the slip ring and make full contact before a charge appears, at least that is how it looks. Usually with stock regulators it takes a few seconds for the warning light to go out. This time it took several tries, a the purchase of an unnecessary new regulator and five minutes of determined revving at high rpm to get it working. However, overall, I am greatly happy with this setup, my battery used to discharge all the time. Just from running fog lights and a radio I had only 11 volts on board. Now I have 13.8 without load and 12.8 with radio and fog lights. I would also strongly recommend everyone to install a Voltmeter in addition to this setup." R.B., (VW Vanagon) Sherman Oaks, CA

Here are some suggestions to follow during installation in well used alternators to help avoid the above condition:
Once you remove the old regulator use some fairly fine sand paper to clean (or "de-glaze") the slip rings. You can do this by spinning the alternator pulley by hand while reaching in the back of the alternator with the sand paper. I have been told by experts that it's recommended to use GARNET paper only (the orange stuff). This is because crocus cloth, emery cloth and silicon carbide papers can eventually damage the slip rings. With crocus cloth and emery cloth, the abrasive material is metallic in origin. It can flake off the paper and get down inside the alternator and can cause internal shorts. With the silicon carbide paper you can develop a contamination problem; the silicon can bond with the carbon in the brushes and cause greatly increased brush wear.

Once your slip rings are clean, you can then pre-seat your brushes if you like (not required, but a good thing to do if you can). Wrap some Garnet paper (200 grit or higher) around a small cylinder around or near 28 mm in diameter and use it as a tool to slowly wear the appropriate arc into the brushes. This will help them to seat faster, preventing sparking, poor wear and it will increase the life of the brushes.

REMEMBER: During these procedures it is best not to handle the brushes with your bare hands. I have been told the oil from your skin can contaminate them. It may sound a bit over-cautious, but do your best.

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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