Red light on, no charging to the battery Grrrrrrr snowing outside Brrrrrr I have the Bosch 074 903 025K 90 amp alternator and a 2.5TDi with intercooler. I looked at loads of threads to see the best way to replace the regulator/brush pack and they all said go in from underneath and remove the alternator, I didnt fancy this as the van is sitting in snow and to remove the belly pan I have to take the bumper off due to the splitter being in the way of it dropping down 
I removed the front grill,5x screws,
Removed the bottom bracket mount for the intercooler, 2x 10mm bolts and 2x 10mm nuts,
removed 2x 13mm bolts each side of the front slam pannel,
Lifted up the panel and rad then pulled it forwards to reveal the alternator.
Disconnected the positive battery cable,
uncliped the plug with the blue cable in and unplugged the temp sensor to make a bit more space,
Removed 2x 13mm nuts on plastic alternator cover (one holds the large black cable on) this also has another 13mm nut behind the cable and removed this too,
Could not undo the bottom cover screw so just bent out of way then removed the 3x screws that hold the regulator/ brush pack on.
That was it 30 mins to remove and all through the top T:
Ordered a new pack through TPS as having worked as an auto sparks for many years a while back I dont ever want cheap copies on my own motors. Im not saying the cheap things are rubbish but original parts are usually the best.
Hopefully this will cure the problem that occurred over night. My brushes do look a lot shorter than the pictured ones and all cables look good. Slip disks are ok with small amount of wear but it has done 180K.
Just wondered if there are any other things to look for on the T4's that might need looking while im doing this?
Cheers all, Kev
I removed the front grill,5x screws,
Removed the bottom bracket mount for the intercooler, 2x 10mm bolts and 2x 10mm nuts,
removed 2x 13mm bolts each side of the front slam pannel,
Lifted up the panel and rad then pulled it forwards to reveal the alternator.
Disconnected the positive battery cable,
uncliped the plug with the blue cable in and unplugged the temp sensor to make a bit more space,
Removed 2x 13mm nuts on plastic alternator cover (one holds the large black cable on) this also has another 13mm nut behind the cable and removed this too,
Could not undo the bottom cover screw so just bent out of way then removed the 3x screws that hold the regulator/ brush pack on.
That was it 30 mins to remove and all through the top T:
Ordered a new pack through TPS as having worked as an auto sparks for many years a while back I dont ever want cheap copies on my own motors. Im not saying the cheap things are rubbish but original parts are usually the best.
Hopefully this will cure the problem that occurred over night. My brushes do look a lot shorter than the pictured ones and all cables look good. Slip disks are ok with small amount of wear but it has done 180K.
Just wondered if there are any other things to look for on the T4's that might need looking while im doing this?
Cheers all, Kev
