Ka24det alternator swap for ca18det rwd

[bias]

For anyone having problems with there stock alternator, I have the fix. No more searching for factory alternator or trying to swap covers. I always feel like giving this time of year so here it is:

Tools needed1. Basic mig welder(I used Easy mig 100 from harbor frieght)2. Vise grips3. Tensioner bolt and nut from ka24de engine4. Metal to make bracket pieces(see in pics not sure of size just what works)5. Angle grinder with cutter wheel6. Factory bracket and all bolts (12mm and 14mm)

Step 1. Remove your factory bracket and grind the area closest to the tensioner mounting location(This is to make better contact for welding)

Step 2. Use grinder with cutter wheel to cut your factory bracket like in picture.

Step 3. Now that piece that was cut you have to flip it and weld it so the tensioner mount location will be on the opposite side( I had to weld both sides) Use vise grips to hold it together.

Step 4. Now this is where you have to make your own judgement. I just went to Lowes and grabbed what I could find to make this spacer. It needs to be thick enough to weld but also the inner diameter needs to fit the bolt you sourced from the de alternator. It needs to be thicker than the ear on the alternator. Maybe an 1/8" not sure just use your judgement

Step 5. You also need to get metal to make this bracket. I just used some scrap metal in my tool box( Not sure of the size just try and make your own judgement) Holes need to be drilled on both ends to fit the bolts.The bolt you use on the alternator has to be flush on the back side

Step 6. Use all the pieces and put them together like this

Step 7. Now you can weld the bracket pieces together( I just used two small spot welds)

Step 8. Now you can cut the bolt

Step 9. Disassemble parts from step 8 and get your factory tension bracket. Take the nut and line it up with the hole on the bracket so the flat side is on the bottom

Step 10. Use the vise grips to clamp bolt then spot weld.

Your done! Now take all the parts clean them up paint them and assemble. You still can use the factory tensioner and with the smaller pulley on the alternator! I forget to put the washer between the mounting bracket and spacer ( First thing my brother pointed out) so please put that in there when you do it

Modified by bias at 7:47 AM 12/19/2009

Modified by bias at 7:51 AM 12/19/2009

Modified by bias at 7:55 AM 12/19/2009

Modified by bias at 8:01 AM 12/19/2009
Modified by bias at 8:11 AM 12/19/2009

[rico05]

Neat idea. Thanks for the other option.

Myself, I will stick with swapping the cover. Looks cleaner.

[float_6969]

Thanks for the writeup!