Changing Alternator Voltage Regulator in V6's WITHOUT removing Alternator - Alfa Romeo Bulletin Board & Forums
 
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post #1 of 11 (permalink) Old 01-13-2014, 01:04 AM Thread Starter
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Changing Alternator Voltage Regulator in V6's WITHOUT removing Alternator

Now before I start I'm not going to get into the debate of how to determine that the regulator is faulty but I am going to say its pretty common for this to be the cause of the Low Battery Charge warning light coming up.

This is meant to be a guide on how to change the regulator in a 147 GTA WITHOUT pulling the alternator out of the car. I believe pulling the complete alternator out is a huge task. Pretty sure it would be the same on all the FWD Busso's except the 155's but my experience is with the 147 GTA.

Sorry to those who do use it, but this job does actually require you to use your brain so I will assume that you know do do things like disconnect the battery, safely jack cars up etc etc

Photos are from another alternator hence some example photos are shown on the bench

Basically you need to undo the alternator so its totally disconnected from the engine, turn it around so you can get to the back of it to undo the nuts and machine screws holding the regulator on.

0: Helpers like mine slow things down somewhat.
1: Undertray and drive belt inspection cover in RH wheel arch off
2: Auxiliary drive belt off
3: Oil filter off
4: Remove small wire attached to lug circled in picture
5: Leave the large one at this stage
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Last edited by MarkAsh; 01-13-2014 at 01:45 AM.
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post #2 of 11 (permalink) Old 01-13-2014, 01:15 AM Thread Starter
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Steps 6+

6: You now need to remove two 13mm headed bolts fixing the alternator to the back of the engine. The bottom one is highlighted in the photo, the top one is aligned in the same fashion but higher up. Its easy to undo but a bastard to get out fully. You have to lever the motor up a little but it will come out
7: Once these two bolts are out you can lever the alternator of its mounting, rotate it around so the back of it is facing downwards and get access to the machine screws holding the regulator on.
8: The big cable mentioned in step 5 may stop you rotating it fully so this is abit of a muck around to get that one off
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post #3 of 11 (permalink) Old 01-13-2014, 01:25 AM Thread Starter
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Steps 9+

9: Now you have the alternator loose you can move it about (with difficulity) so access to the machine screws is easy from underneath.
10: Unto the two 15mm nuts. From memory the one the cable is connected to has two nuts
11: Remove the philips drive machine screw
12: remove the plastic cover (may look slightly different to the one in photo)
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post #4 of 11 (permalink) Old 01-13-2014, 01:42 AM Thread Starter
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Steps 13+

13 Undo Philips headed machine screws highlighted in photo and the regulator should come off in the direction shown
14 That's it off, replacement is reversal of removal.
15 Please for the sanity of the next person doing this job on your car, use some anti seize on the machine screws

16: There are quite a few regulators that will fit and work fine. Im not quite sure why Bosch gives them a different part number but I can categorically say I'm using one out of a Puegeot 406 Diesel and it works fine.

So the Bosch Alternators that use a regulator that will fit are.

These are from Alfa's, Diesel Peugeots and some Citreons

0124 615 002
0124 515 087 (Listed as an Alfa Alternator)
0124 515 090 (Listed as an Alfa Alternator)
0124 615 027

Regulator Part Numbers that will fit the above alternators
F00M 144 189
F00M 145 232
F00M 145 243
F00M 145 252
F00M 145 270
F00M 145 674
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post #5 of 11 (permalink) Old 02-25-2014, 04:21 AM
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Thanks for that. I will store it in my Alfa folder in case, (heaven forbid), I ever have a problem with my GT. How often do you think the problem is more serious?

Current Alfas
2010 159 ti 1750 TBI sedan (red).
2004 GT 3.2 V6 (Stromboli Grey).
2008 159 TI Sportwagon 2.4 JTDM (Stromboli Grey).
1987 75 3 litre (red). My first 75 and now my son's.
2000 156 2 litre Twin Spark, ( Cosmos Blu metallic), my daughter's car.
2000 156 Monza Twin Spark, (Cosmos Blue metallic), son’s girlfiend’s car.
1999 GTV 3 litre 24 valve V6, metallic black, (son’s new car).

Non Alfa
1988 Range Rover Classic Highline 3.9 V8

Past Alfas
1989 75 3 litre, written off by runaway van.
1990 75 3 litre Potenziata (black), now sold & living in Newcastle NSW.
1990 75 3 litre Potenziata (grey, sadly deceased due to fire).
1982 GTV 2 litre, red, (daughter's first Alfa)
2 x 1992 164s, (1 red, 1 grey).
2 x 1988 33s, (both red).
1985 GTV 2 litre, (white).
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post #6 of 11 (permalink) Old 05-02-2014, 03:02 PM Thread Starter
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Problem more serious?

In response to previous comment, really not to sure. I have only really dealt with and heard of this issue
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post #7 of 11 (permalink) Old 07-25-2014, 09:36 PM
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thanks

MarkAsh - Many thanks for this thread - it is well described and w/ nice pictures.
THANKS for you effords!
For me it was very helpful, indeed and saved me a lot of time, else I was to remove the alternator from the car. After reading your thread it was simple job, thanks to your effords!

I can confirm that the described procedure works also for Alfa 156, 2002 /interior FL/, 2,5 V6, with cats in the manifolds.

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post #8 of 11 (permalink) Old 06-05-2016, 01:07 AM
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Suitable for 156 JTS?

Anyone know if this great guide is suitable for 156 JTS too?
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post #9 of 11 (permalink) Old 06-09-2016, 08:50 AM
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I can't the the pics any more so can't say.
At http://forum.alfa156.net/forum/ there are lots of info on various job on the 147/156s.
But from memory you remove RH front wheel and the plastic lining (you probably need to remove RH bolts on the under tray, too).
Then you have asses to the generator. Remember to slack the multi belt before removing the altenator.

Last edited by Erik; 06-09-2016 at 09:30 AM.
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post #10 of 11 (permalink) Old 09-22-2017, 10:22 PM Thread Starter
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Bugger bugger bugger I have the same fault again and have to replace the regulator again. Last time I did put in a second hand one of unknown age so serves me right I suppose. This time I have got a new regulator and having done it before (and used anti seize on the bolts) has made it much easier to do. WHAT I HAVE FOUND IS THAT YOU CAN GET THE COVER OFF AND THE REGULATOR OFF WITHOUT UNBOLTING THE ALTERNATOR FROM THE ENGINE, if the bolts holding the cover and regulator on are not to tight. If they are tight you might have to do it the way described above
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post #11 of 11 (permalink) Old 09-23-2017, 08:53 AM
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In my experience from 20 years in the auto trade and 52 years as a car owner I have only once or so come across defective volt regulator(s).
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