ef alt install

[zookeenie]

have just completed an ef altenator install on a sierra,now has a g16a in it but will probably work for both engines,writing to let you all that are too scared to do this upgrade,that its a peice of piss and you must have a go at it..
did this while i was waiting for the gasket silicon on my sump to dry..
alt cost me 40 buck from the wreckers,pulled it out myself(lazy wreckers!)
make sure if you do this,hang on to the longest bolt,you will need it.
INSTALL:pull off the all the brackets with the alt out of your zook,the bottom bracket is cast,drill the two threaded holes out to 10.0mm so the long bolt(which should be still in your pocket!) slides all the way through,drill all the way through both sides in one go ,that way your holes will be straight(common sense really).
get a grinder with a skinny blade,1.0mm. and cut the steel insert on the inside of the ef alt so that the distance from side to side(inside two mounts)is equal to the outside of the suzuki one.
mount lower bracket and tighten.mount ef alt,but leave finger tight
mount the top bracket(the one with a slot in it)as it was before,mark where the alt touches the bracket and grind away enough metal to give you some adjustment on the bracket(10 to 20 mm is heaps).
give it a test run,see how the belt sits,if its on a g13 ,you will have to change the pulleys over(sucked in!)g16a lines straight up with no adjustment needed.
ELECTRICAL:the two small wires on the sierra loom where connected as follows,dont think it matters too much anyway!.the black wire from the zook went to the bigger of the two on the ef alt which goes to the ig sw,and the white one connected to the grey wire on the ef.(Warning Light Circuit Supply)
The main supply wire from the zook(large white wire with yellow stripe goes back to the main loom and is crimped somewhere near the battery,dont bother pulling it out,cut off the lug und tape it up over the loom with some black elec tape(Dont skimp,as this will still be live!)
Run some larger cable back to the batt+ from the bolt on the alt,at least half the size again,you are going from a 50A alt stock<to a 110A.Get the picture..More Amps,Bigger Cable!..I had heaps lying around(sparky) but you could use cheap jumper leads,as they are good for around that..if in doubt,run two!
once its all hooked up,start up car and check voltage on the batt(should be around 14.6 give or take,now wind up the throttle,volts should stay around the same figure(it will float up and down a little as the revs change.turn everything on,lights on high beam,fan,wipers stereo the lot.
volts should stay about the same regardless of load.If you have a DC ammeter,good time to see how much spare capacity you have left on your new alt..Dont load it up to the hilt though(you dont like being worked flat stick do you!)
turn off the engine,battery should now be at around 13.8v...HAPPY DAYZ
Is that silicon dry yet!

[przooker]

With the electrical plug connections, the yellow one from the alternator( the thicker one) goes to the ignition feed, this is the voltage sense. Check with a multi meter that it is the same voltage as the battery, because if it is lower, then the alternator will overcharge. The other one is for the warning light circuit. To double check the suzuki wires, use a test light with a bulb and the one that lights up bright is the ignition, and the one that lights up very dull is the warning light wire. The belt used is a 4pk830. Its 30 mm longer than standard. I didnt have to grind any off the top bracket, it fitted straight on. This is for a g16b. It is real easy, just ensure the hole in the bottom bracket is drilled straight, otherwise its a pain to get on.