Adjustable Voltage Regulators

Return to Main Page       UPDATED: July 11, 2008

	Web www.davebarton.com

Adjustable Voltage Regulators
for your Volvo/Bosch Alternator
   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.

ALL IN STOCK
 

This style regulator works very well with the Volvo 240/260 series cars (especially 240 Turbos) since the alternator is very low in the engine bay and access to the back of the alternator for adjustments can be difficult (impossible in a 240 Turbo).  Also on a 240 the hot exhaust manifold is close to the alternator and by putting the remote regulator a distance away from this heat source, it will operate more consistently.  This is just one reason why having a remote adjustable regulator mounted somewhere more convenient is such a nice idea.  Scroll down to the installation tips to see how I installed this kit in one of my own 240's.
(Please read WARNING below regarding installation)

Will fit all Volvo 240/260 '75-'93, 740/760 '84-'92, 940/960 '91-'95.
I have found that these regulators will also fit other Bosch external fan alternators.  This particular type fits those with 28mm slip rings (A 32mm slip ring type is also available in an Internal Regulator type only... please inquire).  Most 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 if you are not sure.

Ordering: External Adjustable Regulator Kit (select Standard Harness or Custom Length) Price: $44.00 plus shipping Order Quantity: Standard 32" Harness Add Custom Harness $10.00   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 $35.20 each plus shipping) Your discount will be computed upon check-out. Need a Replacement Brush Assembly? Price: $12.00 plus shipping Order Quantity: 20% discount applies on orders of TWO or more. Shipping for External Regulator Kit 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 $16.00 Other International Shipping: Int'l Shipping Options Global Priority Mail Int'l $20.00                                              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): $17.00 (estimated delivery in 5 to 10 days) International Shipping (all other countries):  International Priority Mail insured: $23.00 (5 to 10 days)

 
NEW 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 $16.00 Other International Shipping: Int'l Shipping Options Global Priority Mail Int'l $20.00                                              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): $16.00 (estimated delivery in 5 to 10 days) International Shipping (all other countries):  International Priority Mail insured: $20.00 (5 to 10 days)

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NEW Internal Adjustable Voltage Regulator:  In Stock
This complete regulator/brush assembly can be installed in your alternator in place of your original Bosch non-adjustable one.  It's an all-in-one compact part and can be adjusted to 15 volts.  This style works well in the Volvo 740/760 or 940/960 series cars where the alternator is mounted high (on top) and the back of the alternator is more easily accessible when an adjustment is needed. 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.  This regulator will work in a 240 also, but access to the adjustment screw might be obstructed as mentioned above.  This is a new part, not remanufactured.  (Please read WARNING below regarding installation)

Will fit all Volvo 240/260 '75-'93, 740/760 '84-'92, 940/960 '91-'95.
I have found that these regulators will also fit other Bosch external fan alternators.  This particular type fits those with 28mm slip rings (A 32mm slip ring type is also available in an Internal Regulator type only).  Most 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 if you are not sure.

Ordering: Internal Adjustable Regulator (May 26, 2008: Temporarily out of stock.  Should only be a few days) 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. 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 $17.00 Other International Shipping: Int'l Shipping Options Global Priority Mail Int'l $23.00                                              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): $16.00 (estimated delivery in 5 to 10 days) International Shipping (all other countries):  International Priority Mail insured: $20.00 (5 to 10 days)

Purchasing 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 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: $16.00 USD (estimated delivery: 3 to 5 days), All Other International Shipping:  Priority Mail International insured: $20.00 (5 to 10 days) 20% discount on orders of two or more pieces.

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 Comments:
"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."

The first order of business: disconnect the negative side of your battery.

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.

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 Regarding 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 try to force or install this kind of part incorrectly and destroy it, please don't write me and tell me it simply "fell apart" and must have been defective like this customer did.  Forcing parts like these is always a bad idea.

ALTERNATOR TESTING
If you are using an external regulator with a brush assembly like the one pictured, the below Full Field Test method 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 will 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 external regulator harness I supply with this kit, the wire colors are: D- (BLACK), D+ (RED), DF (GREEN).   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 of the D+ and DF pins. This could be made from an old bad internal regulator unit (just make sure the brushes are still good). 

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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