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Alternators - Standard Vs Upgrade


 
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Lewis
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Joined: 25 May 2006
Posts: 15672
Location: Huddersfield

PostPosted: Thu Apr 02, 2015 13:28    Post subject: Alternators - Standard Vs Upgrade Reply with quote

Having answered questions on a few posts regarding if or not other alternators will fit the 2.8TD I thought this info may be of use:-

Note that you can upgrade the standard 90Ah alternator to a 120Ah or 125Ah unit without rerquiring any wiring or fuse changes. †:D

However different alternators have different widths between the bracket arms on their castings, which may have been made by several manufacturers. Generally the front casting remains the same, with just the rear section being different. Accordingly a spacer is fitted into the arm of the rear section casting to match them to the engine they have been designed to fit.

The front end of the bracket bolt is square and butts up to a flat plate on the casting to stop it rotating. Just keep the bolt head pushed against the alternator whilst undoing the nut. A 17mm socket or offset spanner is required for the nut.

In the photos below on the left is a standard OEM Factory fitted 90Ah Mitsu alternator for the 4M40 engine. On the right is a 125Ah Mitsu Alternator however that alternator is also used on other engine blocks with a wider bracket in the block casting, or in the case of the L400 on the alloy engine front cover plate.


1. Although the arms on the casting are wider the spacer reduces them to fit. †Smile



2. The back of the alternator on the 125Ah is laid out differently, which makes it a bit more fiddly to connect the cables, unless you do it before it is connected up to the adjuster block and the belts fitted. †Wink




3. The back of the 125Ah is deeper and sits further back, plus the earth cable is lower down when fitted and the pulley wheels remain in the same location.




Tips:

Ensure you isolate the alternator from the battery before undoing any cables. If you don't want to disconnect the battery and loose your radio station and internal clock settings then try removing the alternator fuse, either at the battery or the 100Amp fuse in the engine bay fuse box (NB: Wrap some insulating tape around the first few inches of the bonnet stay, in case you catch the spanner on it and blow the fuse †Rolling Eyes :-





Adjusting and loosening the belts: †The forward facing bolt head is the locking bolt and the one facing the wing is the adjuster. A 12mm socket or spanner is required for both. When fitting new belts tighten them so that there is 8mm of stretch, either way, at the midpoint between alternator and engine pulley wheels, to allow for stretching in use.:-






Part numbers:

ME201745 - † † † † Alternator 12V - †90A †- 1994.03.1 - 1995.07.3 - Replaced with ME202755 - All
ME202755 - † † † † Alternator 12V - †90A †- 1995.08.1 - 1997.05.3 -
ME201837 - † † † † Alternator 12V - †90A †- 1995.08.1 - 1997.05.3 - Replaced with ME202755 - All
ME202232 - † † † † Alternator 12V - 120A †- 1997.06.1 - 1997.11.3 - Replaced with ME202756 - All
ME202756 - † † † † Alternator 12V - 120A †- 1997.12.1 - 2004.08.3 - All
ME203546 - † † † † Alternator 12V - 125A †- (used on 3.2 diesel Shogun)
ME701349 - † † † † Alternator Brush Kit † 1994.03.1 - 2004.08.3 - All
ME701346 - † † † † Alternator Rectifier † 1994.03.1 - 1995.07.3 - All
ME701353 - † † † † Alternator Rectifier † 1995.08.1 - 1997.05.3 †- All
ME701716 - † † † † Alternator Rectifier † 1997.06.1 - 1997.11.3 †- All
ME701862 - † † † † Alternator Rectifier † 1997.12.1 - 2004.08.3 †- All
ME701363 - † † † † Alternator Regulator † 1994.03.1 - 1997.11.3 †- All
ME701857 - † † † † Alternator Regulator † 1997.12.1 - 1990.02.3 †- All
ME701986 - † † † † Alternator Regulator † 1999.03.1 - 2004.08.3 †- All
MH014054 - † † † † Alternator V-Belt Set 870x2 (pair) †- £14.25
MH014050 - † † † † Alternator V-Belt Set 880x2 (pair) †- £14.25
MD199223 - † † † † Alternator Belt † For V6 3L

HTH †:D
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Last edited by Lewis on Sat Dec 14, 2019 15:33; edited 2 times in total
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PostPosted: Thu Apr 02, 2015 13:28    Post subject: Google Ads keep this community free to join!


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Lewis
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Joined: 25 May 2006
Posts: 15672
Location: Huddersfield

PostPosted: Sat Jan 06, 2018 14:54    Post subject: Reply with quote

Photomuppet links replaced.  :D
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