Installing a generic VW Bosch 120 Amp alternator on a Range Rover — Volkswagen Eurovan

18 Фев 2015 | Author: | Комментарии к записи Installing a generic VW Bosch 120 Amp alternator on a Range Rover — Volkswagen Eurovan отключены
Passat 95 vr6 120 amps alternator

Genuine Range Rover have always been on the side — I remember a new one for over $700. The situation has significantly in recent years the Parts Sources page for on low cost sources of new and rebuilt Rover alternators), but a number of have lowered replacement by converting their RRs to use cheaper alternators. For example, the Delco swap is common, but requires custom brackets. This kindly contributed by Eric, the installation of a low cost generic alternator, as used on a wide of Volkswagen vehicles, on his 1990 Rover Classic. For this the existing mounting brackets are making the job much easier. time to do this swap is 1 1/2 hours. The procedure should on all pre-serpentine belt models Model Year Applicability

VW Alternator Parts Information


VW Part # 021 903 025 G, more part #s are 028 903 018 B or 028 903 018 C

Bosch Part # 0-123-510-007, -053 (refers to 021 903 025 G)

Remanufactured Part # AL0184X

If you to try this out, ask for 120 A alternator for the VW vehicles.

92-95 VR6 Corrado

94-99 Jetta GLX VR6, Golf GTI VR6 (These are Mk3 bodies).

Passat GLX VR6

93-2004 Eurovan VR6 or / Rialta RV camper.

Some parts stores may not carry the 120 A alternator, they may have a 90 A or Valeo brand.

These 90 A are common with most of the VW only select VWs had a 120 A alternator.

the redesign of VWs models from there are newer versions of alternator. The main difference is the electrical plug is now proprietary and shaped. The other difference is the black plastic cover, on which model it was fitted to, may an air intake. Many newer alternators have this due to the engine bays, some are water cooled.

DO NOT USE a Valeo alternator with your RR. You have a problem with the pulley offset, the belt not line up with the p/s pulley. Try a rebuilder for a suitable pulley and if your determined to use the Valeo

This Bosch 120 A alternator on average for $220 (rebuilt), a core charge extra. they run $450-675.

I had this one around as a spare for my VR6 Jetta. better, is a 150 A Bosch alternator, exact case dimensions and type.

This is optional on the VW Eurovan and the / Rialta RV camper.

There is one to this alternator, its the rear noise.

Many VWs will this noise start 40K miles, its due to the lack of sufficient If you source a used alternator and to repack both the front and bearings. Please check out the page for a how-to. Bosch repair page.

This is common with VWs using style alternator 70 A — 150 A.

for Modifying the VW/Bosch Alternator

You need to drill the Lucas to 17mm ID so it will fit the Bosch shaft.

The orientation of the Lucas is the same as if it were going on a alternator. No need to flip it it works as is.

The pulley alignment is so that it doesn’t require any I put the Lucas pulley on without the fan or other Lucas hardware.

All you is the Bosch lock washer and The Lucas fan is not used, the Bosch has an internal fan of its own.

Mounting the Alternator

To secure the alternator to the Range Rover bracket, mount the front ear on the outside of the RRC bracket. You will to use suitable nuts and bolts for the mounts and for the upper mount.

The requires some shims or a of about 25mm long. length can vary a bit. due to the sliding rear nut.

belt specified for use with the alternator, Autozone part # is too short and tight with no possible.

I purchased a much fitting belt, Autozone # 15290. This is a 15mm belt versus the 13MM specified in the Autozone parts Infact the 15mm wide fits the pulleys better, sinking like the 13mm The 15290 belt allows for tension adjustment, without too long or too short.

It helps to the bearings from failing do not over do the tension.

There was no to modify the upper Range bracket at all. I did notice the previous owner had used a nut as a this is were the top tensioner bolts to the water pump. for me as I didn’t have to add it. I do not know if the Rover came from the with a spacer there or If not, you need to get a longer pump bolt and use a 15mm to keep the upper bracket binding on the alternators upper ear. This spacer and bolt is cheap, no need to an extender like others with Delco alternators.

The wiring is so simple, once you what the function of the wire is.

colors may vary, but my vehicle had the colors:

Thick brown (battery lead), goes to battery stud ( Bat ). I replaced it a 4 ga. red wire to the firewall terminal.

with yellow stripe to D+ on Bosch alternator (dash

White with slate goes to W on Bosch alternator lead).

No need for the Rover there is no noise heard the radio or CD

(after market system, 800w Sony 4 ch. This Bosch alternator has a built into the rectifier The Bosch condensor is not a serviceable it must be replaced with a new assembly.

I revised these after driving the truck, a realistic test as the alternator is Original measurements were with a cold alternator, after the swap. I originally had wattage 55/60W H4 headlamp now they are 90/100W.

Voltage with accessories off was measured at the alternator while the was parked idleing. Voltage 90/100W H4 E-code Hella and 55W H3 Hella 550 driving lamps on was at the alternator.

I’ve read these Bosch Alternators are hot meaning they put out 120 amp when its Compare this to Domestic which are cold rated, the drops as they get hot. I confirmed this, but I read on a UK website dealing with alternator kits.

I have a Red Top Optima battery, 4 ga. battery to the chassis, starter and firewall

My voltage drop is due to the use of the original battery cables to chassis and to the (they are old). I had originally cut off the old clamps and soldered copper terminals for use with new Gold battery clamps. These new were sourced from a car shop. Only the alternator was made by me, but I did this nearly 5 ago. I’ll have to those battery cables time permits. Its unrealistic to that I won’t have a drop, but I can minimise the drop new cables. Less resistance the old 15 year old cables = more for my accessories.

This is what the alternator look like, with the VW pulley.

This alternator style comes in 70 A, 90 A, 120 A and 150 A versions.

my text and arrows.

This is that part fits on Range Rover.


is a W and D+ plug, its a standard Bosch sensor/ fuel injector

A simple plug to find at any parts store.

That much covers it. A nice from the old Lucas 80 A alternator.

The works the same as if I still had the alternator.

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