Replaced my Valeo Voltage Regulator

[Cruzer]

Wanted to share my experience since I couldn't find a DIY. My lights were flickering and I lost power a few times on the highway (with all my cluster warning lights lit light a x-mas tree). Alternator voltage tested low (12v). Unfortunately, my alternator is a Valeo and the voltage regulator is semi-internal (part #10 in the diagram below) which is harder to replace than the Bosch voltage regulator. Having said that, the VR can be replaced in 30 minutes without removing the alternator.

Here are the steps I followed:
1) Disconnect battery
2) Remove airbox and AFM in one piece (2 nuts)
3) Disconnect two wires on back of alternator (2 nuts)
4) Remove plastic wire housing on back of alternator (2 more nuts)
5) Remove noise filter on the back cover of the alternator (1 nut)
6) Remove alternator back cover (4 bolts). This is tricky but can be done in place. You may need to unplug the harness that sits next to the alternator. Pivot the cover to get it past the tight area between the alternator and the engine.
7) Unbolt the old voltage regulator (2 bolts) and pull straight out.
8.) Assembly is pretty much the reverse.
9) Reconnect battery, reset clock, enter radio code

[lylefk]

Thanks for this, used it just now.

You'll need a 1/4" drive, deep 8mm and deep 13mm for the alternator and a 10mm wrench for the airbox. Screwdriver for the regulator and airbox clamp.

The back cover was tricky to remove, I found that rotating it clockwise 180 degrees did the trick and allowed me to slip it out.

I also had a bit of an issue lining the new regulator back up, guiding it in brushes first and holding it with one hand while starting the screws with the other eventually got it back together for me.

Took me about an hour.