I'm swapping a 1.8 into my 93 and need to know what alternator to use. I tried using the 1.8 alternator but the grounding strap on the 1.6 harness is to small to connect onto the 1.8 alternator. The plug fits into the 1.8 alternator however. Which alternator do I use?

 

Unless you switched ECU's, use the 1.6 alternator

 

I will need to swap the 1.8 alternator pulley onto the 1.6 alternator, Correct?

 

yes.

 

I used the 1.8 alternator on my 1.6 to 1.8 swap. I drilled out the connector to fit the 1.8 alternator. Ran like that for a year and a half.

 

It actually depends on the year of the 1.8 alternator. All 1.6 alternators had the internal voltage regulator. 1.8's(don't know the year) switched over to a voltage regulator controlled by the ECU. Check the 1.8 alternator itself to see if the voltage regulation is wired in.

 

Im using my 1.6 alternator. The 1.8 alternator uses a different belt, so I'm running a 1.6 pulley on my 1.8 engine.
I'm pretty sure only NBs have the regulator in the ECU, but I might be wrong.

 

Im pretty sure that it was only NBs (99+) that had the alternator regulated by the ECU

 

I'm running a megasquirt if that helps

 

I would use the 1.8 alternator and drill the positive lead out a little to fit over it. If you use the 1.6 alternator, you must use the 1.6 WP pulley and the 1.6 balancer. Using the 1.6 balancer on a 1.8 might be fine, but it might be ill-advised, and we all know how important the balancer is to the health of the oil pump.

It's much easier and safer IMO to just drill the connector out.

 

Yup, 99 and up have the regulator controlled by the ECU.