'02 Alternator Replacement--Article from Headlights, Anthony Velleco's great '02 Registry newsletter.

Early 2002s came with a small 35 amp alternator, later models came with a 45 amp unit, which was fine for its day. The car had no power options so the current draw was low. Today, your 2002 might have an electric fuel pump, electric fan, electronic ignition, 100W headlights, and an amplifier for the stereo. A few of these running with your heater blower on high and you have a huge draw on your charging system. Your alternator is too small for your needs and it is going to give up on you, or the bushings will become shot and need replacement. If you haven't upgraded your alternator lately, you should start thinking about it.

One of our members, Ed Weimar, sent me an article written by Rob Berger concerning 2002 alternator replacement options. Rob was looking for a replacement for his Bosch alternator. Trying to find an alternative, he found a GM Delco Remy model #1105 519 85A, which was rated at 107 amps. For $68.00 plus a $20.00 core charge, he bought it. He mentioned that the mounting hole was too big, so he needed to machine a brass bushing and he needed to weld a bracket on the bottom for belt adjustment. Other than those changes, the pulleys lined up and the stock belt was used. The alternator had a built in voltage regulator and a place to hook up the wire for the dash (idiot) light. So here is an option if you are looking for an alternator with a lot of power.

When I needed to replace my alternator, I wanted to increase the output, but wanted to stay with a Bosch unit. The road I chose to take was to install the alternator out of a 530i. I bought it used for $40.00 and just for piece of mind had a shop rebuild it with new brushes, etc. for $50.00. So, for $90.00 I had a good as new, factory Bosch alternator. Now for the good part. This alternator was rated at 55 amps, which does not sound like a lot, but it is a 25% increase. It also has solid bushings--no rubber one to wear out! All this and it bolts right on, just like your old unit. The mounting points are the same and the wiring harness just clips right on. I highly recommend this upgrade. It is a factory unit that bolts right on, no more worn alternator bushings, your headlights and dashlights will be noticeably brighter, and there's a little something extra for some accessories.

--- Thanks to Anthony Velleco and John Temple