Hi Eric,

Ampere-wise 80A or 100A doesn't make much a difference for normal engine operation except maybe when you simultaneously use high current equipments like headlights + foglight + AC + blower (+ seat and side mirror heater too if you have it).


Unless you have another car to use by you'd need to replace your alternator ASAP or you'll keep draining the battery. In my experience, my 1994 940 Bosch car is only good for about 1 hour of driving to look for alternator shop before it runs out of power (this with AC + blower + headlights = Off).


If you have another car to use by you have the time to search/order for a new set of brushes for the Denso. If you have automotive electrician (those repairing starters/alternator/headlight/tail light wiring etc) at your township you could dismantle your alternator bring it over to the shop and have it fixed within a few hours. Otherwise ordering online would take a few more days.


If you plan to get a Bosch alternator make sure the mounting and wiring points are the same. Some Bosch use female spade connector for the D+ terminal, some use ring terminal. But these only require minor modification.


Alternator's depth (front to back dimension) is another thing to consider if you have AC. You may have AC pipes (from the compressor) running close to the back of your alternator. Yes you may use larger diameter drive belt to get it clear of the pipes but soon you'll be out of adjustment range. Get the right replacement in the first place to avoid all these. Otherwise there's not much else to consider for the conversion.


Regards,
Amarin.