Hi
I'll try to explain as simply as possible. A lot of the existing wiring and equipment is redundant, and can be removed. The wiring for the modern type of alternator is much simpler, but you need to take into account the current wiring layout of the van.
First, you need to look at where all the electrical control boxes are
The Warning light control unit, Relay and Alternator control box are all now surplus to requirements and can be removed. However, the following steps must be followed:
1. On the warning light control unit, cut the ends off the brown/yellow wire and brown/black wire and join together (either with a scotchlock or any other method. Make sure the finished thing is well insulated.
2. At the alternator, the brown yellow wire will connect to the smaller of the three terminals on the new alternator.
3. You need to look for where the wire comes through the parcel shelf as shown on this photo. Within the wiring that is coming from here, you will find a thick brown wire (which goes back to the original alternator. You need to pull that out of the loom so you have enough wire to terminate it onto where the existing brown wire connects onto the terminal in the fuse box (You can see it coming out of the top left side of the fuse box). There is only one brown wire there, and you will need to put a suitable terminal onto it (a 6.3mm terminal). This wire carries all the power to the lights and the ignition circuit and all electrical accessories.
4. Now, you need to run a new cable from the fuse box to the solenoid (replacing the existing brown wire to the alternator). This need to be a suitable size cable, capable of carrying at least 35 amps (depending on the rating of the new alternator you have). This will need to go onto the side of the solenoid THAT IS NOT CONNECTED TO THE STARTER MOTOR).
5. Now, you need to run a shorter cable of the same thick wire between the same side of the solenoid and one of the large connectors on the new alternator.
Now, that all makes sense to me, but I am not sure if you are following? It is important to run the main supply from the alternator to the solenoid. This keeps the main current used to recharge the battery out of the main wiring circuits.
If you are interested, I can make up some a suitable kit of wires and connectors for you to be able to do this yourself (with slightly modified instructions). I reckon £15 including postage would cover it.
Email me if interested.
Cheers
Andy
