Replacement Alternator problems

[dooooogle]

I need a new alternator for my DG 1.9 petrol and I am having trouble finding an exact match. Current one that I have removed has part number:

VW 025 903 023B this claims its a 14v, 65amp (bosch 0 120 489 364 441)

The problem I have is that the pully on mine is in-line (See picture) and all the replacements that I have found have the pully on an extentsion. Iv found one on JK which is 90amps - anyone know if this going to fry my electrics if I was to fit it? Van worked very well with 65amps with leisure battery and 12v fridge.

Pully is next to the fan, all the pulleys I have seen are on an extension

IMAG0652_edit0.jpg

Alternator was removed as bushes are fried, I have ordered some replacements but again cannot find an exact match so will see if the brickwerks do the job.

Bushes have a big difference in length. The short one is oxidised and the copper ring on the alternator alternates clean / black / clean - I think this could be the cause of my problems

IMAG0659_edit0.jpg

[kevtherev]

You don't need to replace your alternator
the brush pack replacement will do the job

It's odd that you have a 65A alternator though, as 1.9's were fitted with a 45A alternator. (green sticker)

If you must fit a 90A alternator then they were also fitted to 2.1 caravelles and golfs.
There will be no issues with your electrics.
Shop around for it euro parts and GSF do exchange units but a local alternator repair shop will be able to refurbish your old one
I have a place here in Wolverhampton he charges £15 for a brush pack

[kevtherev]

all these part nos. are for a 1990 van

025903017 X
alternator
45A /

(1) 068903017MX
alternator
65A /

(1) 068903017NX
alternator
65A BOSCH /

(1) 026903017AX
alternator
65A /

(1) 068903017PX
alternator
90A /

(1) 026903017BX
alternator
90A /

(1) 068903017PX
alternator
90A /

(1) 068903031RX
alternator
90A /

[kinnoir]

I've been looking at a replacement alternator for my van too. I have a 1990 Autosleeper. It has exactly the same alternator as yours. I guess it's 65 amps rather than 45 because of the leisure battery and fridge.

Buy Parts By (http://www.buypartsby.co.uk/" onclick="window.open(this.href);return false;) do a replacement one for £87.60 + VAT plus £50 surcharge. Their part number is CA 911 IR.

I also got a quote of £79 + VAT from http://www.alternatormart.co.uk/" onclick="window.open(this.href);return false; for a NEW one. I spoke to them on the phone and they said that the pulley can be swapped over from the old unit if it's different. I'm not wholly convinced by that, though.

My local VW agent said the part number we had has been superseded by "several others" this'll be the ones kev refers to I expect. VW wanted £195 + VAT for a new one.

I'm getting my alternator checked out, but I'm sure it's knackered. The brush pack looks OK. You can have it if you want it.

Neil

[dooooogle]

Thanks for the link Neil. Im glad im not the only one with this problem. I think buypartsby are the guys to go with, their pictures are spot on.

New brushes arrived today from Brickwerks, however its now freezing outside so I will wimp out and refit the alternator at weekend to see if it a simple brush change fixes it. Iv added a pic in the event for reference if anyone is interested in looking at burnt out bushes.

IMAG0662_edit0.jpg

I contacted alternatormart, and few places around Bristol (GSF, Euro parts, Camberly Auto etc) - they all suggested changing the pulley over, however this invalidates the warranty.

If the brushes do not resolve the issue, I will be going to the local auto electricians followed by your link.

Dave

[DevonAid]

Sorry for being dim, could someone direct me to Brickwerks alternator brush pack please? Have had a good look but can't find them.

Having borderline charging issues with our '85 van fitted with a 45A alternator, voltage output low, especially when on load

Many thanks

[kevtherev]

you're not dim
I can't find the brush pack either

[dooooogle]

Im dim - VW Heritage, not Brickwerks - Sorry sorry sorry

http://www.vwheritage.com/vw_act_shop.p ... try_GB.htm" onclick="window.open(this.href);return false;

You can also have a giggle at my expense along with the guy in my local parts shop who laughed when I asked for alternator brushes. Not sold these here in over 10 years.

Brushes now fitted, Alternator re-fitted, new belt and van now starts. Just been out for a spin in the dark and I can just about see a faint glow from the battery light if I look hard enough.

[dooooogle]

Also you can also get it for twice the price from JK

http://www.justkampers.com/shop/t25/ori ... 12786.html" onclick="window.open(this.href);return false;

[DevonAid]

Cheers for the correction and web links

Good luck with getting your van sorted.

[Nicola&Tony]

Very useful thread, thanks for the info and photos.

I've been to gsf this morning and they tried to sell me a replacement alternator with a long neck on the pulley, but mine is the same as the one in the photo (except 45 amps). Fortunately they could also recommend somewhere local for a refurb. It sounds like bearings that are going on our alternator 'cos it's not charging properly and it's making a noise.

Tony

[Cruz]

I have a place here in Wolverhampton he charges £15 for a brush pack

There was a number for a place in Birmingham that sends regulators by post for a tenner. Can't find the details though

[Red Westie]

Yes..I originally posted the link.
Mine was fitted over two years ago and still going strong although Kev apparently had problems with the one he bought......
Anyways here it is:


Contact details for the regulator/bush pack supplier:
Vehicle Electrics (Birmingham Ltd) The aftermarket number for MY alternator (yours may be different) was VERG 1009 but they have a list to cross reference your particular aternator number against so you can order the correct item. Mine was £9.70 incl post.
CONTACT VEHICLE ELECTRICS, 166 STOCKFIELD ROAD, ACOCKS GREEN, BIRMINGHAM, B27 6AU. TEL : 0121 706 0688 EMAIL: VEHICLEELECTRICS@AOL.COM

Martin

[mfunsta]

Hi, I'm resurrecting this thread as I would like to uprate my existing 45A alternator on my 1989 1.9DG to a 65A one.
Using the part numbers kindly supplied by kevtherev 9see below). Will any of the 3 65A options fit or are there subtle differences?
I think that the MX refers to one fitted to the TD variant, would that be a direct swap, would I need to transfer the pulley/fan from mine.

025903017 X
alternator
45A /
(1) 068903017MX
alternator
65A /
(1) 068903017NX
alternator
65A BOSCH /
(1) 026903017AX
alternator
65A /

Any help would be appreciated, cheers

[kevtherev]

your alternative alternator would be the 90 amp one. As the 65 A one is for a diesel...2.1 DJ, or golf...
068903017PX


I fitted one and found no difference in anything, have now returned to 45 amp