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Step #1 is ALWAYS to disconnect the battery negative cable and secure it aside where it cannot touch the post until you're ready to hook it back up.
Your new alt. may have different terminal connections than the original Volvo, but Rule 308's description of the wire destinations still holds. There will be a nice, solid ring terminal on the fat Red wire and there should be a mating stud and nut on the alternator (B+). The thin Red wire goes to D+, and, as it carries only a very small current, you can make up whatever connector you need to hook it up.
The Blue wire to Ground is a potential culprit in poor charging performance. Although it is a smaller gauge than the fat Red, it carries as much current (up to 70Amps on your original 1984 Bosch). The reason it's a lighter gauge is that it's only about 8-inches long, and hangs out in the breeze. The fat Red is about 5 feet long and wrapped in a bundle, so it needs to be thicker to carry the same current without overheating. MAKE SURE the Blue has its
(usually) ring terminals firmly fastened at either end to the copper strands, and that they are secured at their respective ends to the alt. case and the engine.
--
Bob (son's 81-244GL B21F, dtr's 83-244DL B23F, 'my' 94-944 B230FD; plus grocery-getter Dodge minivan, hobbycar 77 MGB, and a few old motorcycles)
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