Old Ducy alternator

[lindbergh]

I am finally getting around to replacing my old Ducy alternator. I purchased a new alternator from DMCH and have a question. The new alternator has one wire (brown/red stripe) coming out of the plug, whereas the old as 2 wires coming out of the plug. Which wire gets spliced into the new 1 wire and where does the second wire on the old go? Thanks.

[DMCMW Dave]

I am finally getting around to replacing my old Ducy alternator. I purchased a new alternator from DMCH and have a question. The new alternator has one wire (brown/red stripe) coming out of the plug, whereas the old as 2 wires coming out of the plug. Which wire gets spliced into the new 1 wire and where does the second wire on the old go? Thanks.

Connect the wire from the new one to the brown/yellow wire. Cut off the solid brown and tie it back. It doesn't go anywhere.

[lindbergh]

^ Thanks!

[Rich]

Dave answered the wiring question.

Care to see the complete factory instructions for retrofitting the Motorola 90A in place of the Ducellier 80A? See ST-26-11 on pp 100-102 of the first .pdf. in this list, "DMC-Bulletins-Hybrid":

LINK: http://dmctalk.org/showthread.php?2866 (http://dmctalk.org/showthread.php?2866-Searchable-Workshop-Technical-Bulletins-and-Volvo-Engine-Manuals&highlight=hybrid+technical)

This service bulletin explains the wiring mod plus some wiring safety notes you should pay attention to, also calls for using the matching tension adj. bracket P/N 110102 for the Moto which is somehow different from the Ducy's tensioning bracket and is fitted in reverse (slotted end is toward the engine, not the alternator). Not sure whether you have the Moto bracket nor am I sure whether it matters which bracket is used in which orientation for this swap. Others can feel free to comment. Ours got the swap at the dealer per this bulletin.

[lindbergh]

I have the service bulletin and now understand the brown tracer wire gets cut and tied off and the yellow/brown gets attached to the 1 wire on the new alternator plug. I get lost on step 6 which says "disconnect blue engine harness plug (Figure B.) and cut back brown wire to sheathing". The problem is where would this blue engine harness plug be? Unless it is hidden somewhere remote, I cannot find it Is the blue engine harness plug's brown wire the same as the brown tracer wire coming off the old alternator plug or is it something totally different that also has to be cut and tied back for a total of 2 brown wires that need to be disconnected?
I think I understand the mounting difference and I do have the bracket mod (but have not gotten the different belt yet). Thanks!

[Rich]

I have the service bulletin and now understand the brown tracer wire gets cut and tied off and the yellow/brown gets attached to the 1 wire on the new alternator plug. I get lost on step 6 which says "disconnect blue engine harness plug (Figure B.) and cut back brown wire to sheathing". The problem is where would this blue engine harness plug be? Unless it is hidden somewhere remote, I cannot find it...

Yes, it's hidden a bit.

How to find it: Remove the black plastic cover that's clipped to the right rear corner of the engine bay, the one that covers the electrics, including the ignition coil. There are a few bulkhead connectors under there for the engine harness - including the blue one.