One useful option is to get an adapter bracket from me that allows most
common 90 Amp Bosch alternators ...like the ones fitted to every waterboxer
vanagon, 83 to 91 , to be bolted in place on your stock diesel vangon
engine.

three advantages -
- very common alternator.
- more amperage charging
- you get rid of the molded plastic alternator wiring plug that DV's use,
that wear out and can't be gotten anymore easily, or at all.  I have maybe
two good used ones, but it's a old dedicated part that you eliminate going
to the more common 90 amp alt.

So that means some minor wiring modification ........just standard crimp
type wire connectors.
and swapping over a DV alternator pulley onto the 90 Amp alternator. There
may be a slight spacer washer or two needed for belt alignment ..and I
recommend tightening the alternator pulley nut with an impact gun only.

but that's one solution.
I also have a few used stock DV 65 amp DV alternators if anyone needs one.

Scott
www.turbovans.com

----- Original Message -----
From: "Poppie Jagersand" <poppie.jagersand@YAHOO.CA>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, May 24, 2011 10:22 PM
Subject: Update on the alternator story

> So I just found a note on busboys web site that might explain the short
> life of my replacement regulator.
>
> --- On Sat, 5/14/11, Poppie Jagersand <poppie.jagersand@yahoo.ca> wrote:
>> I have two regulators, a round Bosch and an square unnamed.
>> The Bosch ran for 15 years, then brushes wore a bit short,
>> so I replaced it in the last trip with the aftermarket, that
>> I had pulled off another alternator (but given the brush
>> length must be near new). This worked for about 400km while
>> I drove home, but quit in the next trip.
>
> Here is from busboy's site:
> -------------------------------
> http://www.bus-boys.com/charging84diesel.html
> Y.  070-903-803A  Bosch Internal Voltage Regulator, Rectangular Housing
> with Brushes (30062), 1981  $18.00
>
> Z.  068-903-803B  Bosch Internal Voltage Regulator, Round Button Housing
> with Brushes (30091), 1981 to 1984  $53.85
>
> NOTE: Voltage regulators must be installed like for like. Do not install a
> round button housing regulator into an alternator originally equipped with
> a rectangular housing regulator or vise versa.  Damage will occur to both
> the regulator and alternator if these parts are mis-matched.
> ------------------------------
>
> The Bentley manual of course said nothing about this. Bentley only said
> that a condensor should be fitted when replacing with a newer regulator if
> not already there. But I had that.
>
> There seems to be a zillion different part numbers for the Bosch
> regulators, many which are likely compatible. Some that are not. Would
> this be the right replacement for the 65A Diesel alternator?
>
> http://cgi.ebay.ca/ws/eBayISAPI.dll?ViewItem&item=230566083676&ssPageName=STRK:MEWAX:IT
>
> I agree with Dennis and others that it's time to start saving for a
> rebuilt. But I should have a working spare voltage regulator also. And
> that is a small thing that can be mailed to me quickly. Figuring out where
> to best buy (and how to ship at a reasonable rate -- I'm in Edmonton,
> north western Canada)
>
> Another alternative is to look for a used alternator in low milage junk
> yard cars.
>
> Do the alternators from any of the newer VW or other cars fit the Vanagon
> Diesel?
>
> I understand that a lot of the 80's VW had a similar alternator housing to
> the Vanagon Diesel, but I may need to change the sprocket. However these
> are likely to have alternators as worn as mine.
>
> Thanks,
> Martin (and Poppie '82 Westy 1.9TD)