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I had the same issue a few months back. The voltage regulator ($60 eeuroparts.com) was my problem. It is inside the altertnator, and easy to change after you get the alternator out (not enough clearance to get behind it while it is in). I actually removed the alternator but just left it down in the compartment ... I still can't see how anyone can fully remove the alternator without removing other major components.
The trick to getting the alternator out (2 hex bolts ... 8 MM?) is to remove the tensioner and tensioner pulley as they "hide" one of the alternator bolts. Even then, the clearance to get at the two alternator bolts will try your patience a bit, but it is do-able. Another note is that there are 3 nuts to remove from the alternator cover PLUS 3 snap like clips on the side of the plastic cover to loosen before the cover comes off. Haynes didn't mention the clips, and I had a beast of a time finding them since I was going on "feel" mostly since it was still down in the bay.
Voltage regulator at low rpm's gives the charging light because the points are worn. As the rpm's increase, better contact/more revolutions turn into better charging. That is why the light goes out after you get up to speed, etc. but probably re-appears when idling. Is this what you experience? After changing the regulator, this problem totally disappeared for me and all is back to normal.
Hope this helps. Sorry it is so cold out .. where are you?
sotapop
'96 900S 5 speed 126K
posted by 24.123.11...
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