I believe I have a faulty alternator ground wire. Car failed an alternator ground test that I did. Upon a physical inspection, I noticed that the ground wire's insulation at the back of the alternator shows the effect of high heat at the crimp. Haven't pulled the ground wire off yet. I can't find a reference source that notes the gauge size of the ground wire and its length. I did pull ground wires off of a 740 and 940 this am during a visit to a PNP. Both wires differed in gauge.

When I installed this Bosch rebuilt alternator last year, I did notice that the ground wire seemed taut between its connections, perhaps because the new alternator is not an exact copy of the original with a slightly more distant path between ground points.

I might consider a custom built ground wire to specified gauge and longer than the original, or a 740/940 if they are longer. Any one have information concerning the original ground wire or recommendations to take at this point?

For the fun of Volvos,
Mike
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'92 245DL, '90 760 GLT