Matt,
 
I'll just paste in a well used set of instructions from my tech collection - shout if you don't understand any or some of it.
 
First thing to do is to clean up all of the wires at the old alternator end and also identify the wires at the connector plug at the Hitachi regulator. wiring in Bosch alternator to the stock loom is a doddle.
 
regards
Terry
 
----- Original Message -----
From: Terry
Sent: Saturday, November 04, 2000 3:33 PM
Subject: RE: Bosch IR Alternator and Electric Fuel Pump Wiring!!

Zac (& someone others wanted this, Michael & Paddy),
 
Disconnect both battery terminals
 
Alternator wiring (Bosch IR)
 
White/Red (thick wire)  > B+
(I recommend if you have over 300w headlights & a mega amp etc that you run an extra 6 mm shielded wire from B+ to the Starter Solenoid as the stock 510 loom wire is rated at 35 amps and turns into a cigarette lighter with the high draw and charge that your Bosch alternator is capable of.
 
Yellow > Ind
Black (-) > (E)arth (some Bosch don't have a terminal so just use the screw on the back that's for a suppressor.
 
White/Black (Field) > not used
 
Suppressor
 
Connect the barrel to the Alternator body and the wire end to the B+ terminal. A suppressor is not required at the old external regulator end so discard if one is fitted.
 
External Regulator (Hitachi or Lucas)
 
Pull the connector plug at the regulator
Make up a jumper with 2 male spades and bridge Yellow to White/Red in the plug on the loom side.
Connect battery and start your engine. Check that the alternator is charging with a multi-tester and load test it with the lights on.
 
Fuel Pump.
 
Wire the relay thus:
Pin 30 - fused power from battery (4 mm)
Pin 85 - Earth (2 mm)
Pin 86 - Ignition (2 mm)
Pin 87 - Pump (+) (4 mm shielded)
Pump (-ve) to Earth (2 mm)
 
* By shielded I mean run it inside that black stuff that's used on modern day cars that protects wires from insulation damage.
 
regards
Terry
-----Original Message-----
From: [EMAIL PROTECTED] [mailto:[EMAIL PROTECTED]On Behalf Of Matthew Cherry
Sent: Monday, 24 February 2003 6:12 PM
To: [EMAIL PROTECTED]
Subject: URGENT alternator probs

hiya listers ... this is kind sorta very urgent ............ if possible .......... does anyone know how to change a 1600 hitachi alternator over to a bluebird bosch alternator ..(this bosch one is going onto the 1600 of course) ??????????? & if so ... how? this is sorta urgent as i said....  so any help would be excellent !!!!!!!!!!! cheers to y'all
Matt

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