I went with the cheaper Bosch unit myself for my M3, and it's been working well for the past 4k miles.
If the belt was melted to the alternator pulley, there was enough friction to melt the rubber. Simple answer, replace the alternator.
Also, my 90A Bosch alternator is about the same size and weight as my old 65A Bosch alternator. Going to a 90A alternator is a great cheap mod.
I did this on my mk1, along with a 90A Bosch alternator (AL49X ?) and a variable voltage regulator to get 14V. Also, I replaced all the tail lights and side markers bulbs with LED bulbs (superbrightleds) . This greatly reduced the amps drawn from the alternator.
Get a factory Denso if you can but if not the O'Reillys alternator are good quality, we install a few a month and haven't had a comeback.
My alternator just went on my 2008 FJ TT, and I ended up getting a Denso alternator, which works great, but I o nm ly bought it because it was the only one in town.
Get a DENSO brand remanufactured alternator. Parts store house brands are shit.
I just replaced mine last week! I bought a remanufactured Bosch from FCPEuro. Looked brand new. Also was a pretty easy DIY.
Funny thing is, the Bosch alt. I had in the car at the time is sitting in the car in my driveway. Okay, I replaced the brush pack a few times. The 90 Amp alt. itself is at least 10 years old, if not more.
We've had all sorts of problems with Bosch reman alternators. They worked really well until Volvo put the alternator on the CAN network. The reman ones have a ton of trouble making the right charging voltage.
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