There are two different types of alternators/regulators.
On some years, can have both oval or rectangular. (warning on my W/D website)
I think you need a different part and not a different plug?

 

Bosch has a technical hotline that you can call and enquire as to what the current part number is for replacement of the OOM 145 280 VR with round connector that you have. Check the Bosch website. You may need to leave a message, but someone will get back to you within a day or so and provide an updated part number for the proper replacement.

Last summer I purchased the following rebuild kit from Maniac Electric Motors in Texas that has the round connector VR, and the Bosch helpline confirmed for me that the VR included in the kit was the updated one. Fwiw, I paid $59 for the kit last year but it is now $99. I have not yet replaced the VR or tried to rebuild the alternator.

Alternator Rebuild Kit for 2004-2006 BMW 325, 330, 2003-2005 Z4 120 Amp Bosch Type without AirDuct (With Original #s 0124515105)- 13986RK

<h3>Description</h3> Alternator Repair / Rebuild Kit With Voltage Regulator, Bearings, Brushes Tolerance Cap and Slip Ring <br /> <ul> <li>OEM Bosch Brand Voltage Regulator with Brushes, 12 Volt, TERMINALS 'BSS' - 'Dummy', Replacing F00MA45219, F00M145280, F00M145679, OTHER 230-24128, ABO6095...

www.maniacelectricmotors.com

 

As my odometer passed 260,000 miles, it occurred to me that the last four cars I have owned that had Bosch alternators have all worn out the brushes in the alternator at about a quarter-million miles. Rather than wait for the Charge warning light to come on and my alternator slip rings to get fried from arcing with worn-out brushes, I bought a new voltage regulator (hard to find brushes sold separately). The attached photo compares the two regulators, one below with new brushes and one above with very worn brushes. View attachment 930549

The RUB, however is that the new regulator, Bosch Part # F00MA45236 has an electrical socket that is shaped differently from the one on the old regulator, Bosch part # F00M145435. I am off to Pick-n-Pull to see if I can find the correct plug to fit the new regulator. A search on the internet for my original part number reveals that only Australian and Eastern European vendors carry it. I wonder if my wagon ended up with this odd alternator because so few wagons were shipped to the US.

Not sure about the Bosch but you can buy the Valeo brushes and just replace them. You do need a soldering iron and some soldering skills. They do look the same.
Have a look around. Google "ebay alternator voltage regulator brushes". They are pretty standard. Might even be able to swap them over. I can't see from your pictures.

 

I soldered new brushes into a regulator on one of my Volvo's, but the correct brushes were hard to find.
I have been looking at my old regulator and wondering if I can pry it open and solder in the new brushes from the new voltage regulator.

 

If it’s the plug on the VR that’s different, you do want a different part. Mine has the oval shaped plug. Most have the rectangular plug, and most parts sites and stores will only show the rectangular as compatible with an e46. The VR you need is the same as on a 525i E39 and similar. They’re honestly probably exactly the same part with a different plug for whatever reason (very GM-like of BMW tbh) but the correct part is like $30 and imo not worth soldering on a different plug that may or may not work.

but I know it can be bought on FCP euro and ECStuning

 

I believe the Bosch VR brushes are not replaceable as a practical matter due to how the housing is constructed. No access to where you would need to solder the new brushes.

Finding the correct oval shaped connector was tough, and the BMW part number was not reliable because it turns up a square connector on most auto part websites. When I was looking there was lots of confusion and misinformation, even on fcp euro. Square connectors everywhere but almost no round ones.

 

BMW Voltage Regulator - Bosch 12317515319

BMW Voltage Regulator - Bosch 12317515319

www.fcpeuro.com

 

Yup, that looks like the one ... not specifically listed as e46 compatible, which is why it's so hard to figure out.

 

Yep, OP, I banged my head against a wall on this one twice actually. But for whatever reason, some MS45.1 325i cars came with this VR. Sedans, wagons, even coupe/convertible apparently from this thread. But a tiny number of each with no real logic. You car wouldn’t happen to be from around March 2003, would it?

 

I think those are the Z4 VR's that made it into the E46 production line. There's a post or thread about it here somewhere...

 

Fwiw, the two e46's I maintain are March and April 2004, 325i with gm transmissions, and the oval shaped Bosch VR. I think my friends 2004 330i (with gm transmission) also has the oval shaped Bosch VR, but not 100% sure offhand.

 

As my odometer passed 260,000 miles

Wow, I didn't know that the brushes could last this long. On my previous E46, I was about to replace them at 200k miles and I thought that was a rare case. Most people have alternator issue at less than 170K miles.

 

Thanks folks for all the info, particularly Mario0617
It happens that I had committed to a course of action before reading all these, so we will see how it turns out.

I called Bosch Automotive Parts, and was told that my part number was discontinued with no replacement listed.
I asked if I would be OK cutting the rectangular plug off a junk yard car and soldering it on my car, and of course the guy at Bosch had no idea.
He suggested that I buy a new Bosch alternator which he assured me would have the correct shaped plug.
I asked him what the part # was on the voltage regulator on the new Bosch alternator. He could not tell me.
He told me that an authorized service center could find the correct replacement part number even though he could not,
so he gave me the phone number of a service center near my home.

The fellow in the service center was very helpful. It took him about 10 minutes, but he said he could get me the correct replacement part.
It was clear that he was not going to tell me the part #, and he is charging me $99 for a part that I probably could have found for $55 had I known the part number.
He was very helpful and I said I would buy it from him, so I will. I will pick up the part on Monday and try it. If it works, I will post the part # here.

 

You could just take photos of the part then buy it elseware.

 

Sure but what about the mouths needing food at the BSC.
Isn't their time worth something?

 

The one he sold me is different from the one that Mario0617 suggested. He sold me a F00M144147. I don't know where he got it but when I search on that part number, it seems to be for sale only on eBay and lists in the eBay ad as being for a 120A alternator in a '06 or '07 Mercedes C Class. It fits the plug on the car and so far it seems to be working.

 

If anyone here has an e46 with the usual (rectangular plug) voltage regulator, and figures they are about due for a new one, I have a new Bosch voltage regulator that I got from ECS that I will sell for half price.

 

I know this is an older thread, but regarding FOOM 145 280 (top one in first picture in op), which of the two pins is pin 1 and which is pin 2? Can anyone tell me that or tell me how I might be able to find out? Thanks!