I need a write up for putting a high output alternator from a ZJ into my XJ. I know that there are a bunch of them out there, but I can't find them. My NAXJA membership has been terminated due to inactivity, and I don't plan on reinstating it, so I need you guy's help here. TIA!!

 

160A Durango Alternator.
http://www.naxja.org/forum/showthrea...put+alternator

136A ZJ Alt.
http://www.bc4x4.com/tech/2004/jeepalt/

 

Thank you Frank!!

 

Frank to the rscue once again.

 

That was the thread I was talking about too. I even posted in it, before NAXJA nuked my acct!!

 

I can tell you from experience that the bigger alternator is a tight fit.


I put the 136 amp in my 97 XJ. I had to grind the bracket, the block, and the timing cover to get everything to fit. And I had to re-clock the black plastic piece for the wire (on the back side).


It's definitely spooky trimming the block and timing cover. A carbide burr and a pnuematic grinder are your friends here. A whiz wheel (angled grinder & roloc holder) with a sandpaper disc is also very handy.


Take your time and you'll be fine. If you need some pics of how close it is, just ask.



FWIW ... the 136 amp alternator that I purchased puts out 162 amps (max). I had a stock output reman that died ... so the auto parts store let me upgrade to the 136 unit after I paid the difference. 52 bucks got me extra amps and a lifetime warranty.



Joe

 

Cos .. your profile says you have an 87 XJ. That would be a Delco alternator. You can't use the 'denso style there.


Unless I'm missing something somewhere ?



Joe

 

It would be the OEM piece Joe, as I have not upgraded that. So what are the differences, and can they be overcame. My alt is toast, and I want to get the best bang for the buck when I replace it, thanks much!! I have time to do a little sumpin sumpin, but need to know the best route to go...



Yeah, more set backs....me likey!!

 

The Delco alternator is "self regulating" for lack of a better term. The regulator is a replacable part on the alternator. The Denso unit has no regulator as the computer does the work for you. Obviously, the case shapes & associated brackets are different too.



How many amps are you wanting? I have some alternator books here and I can find you applications that will give you more amps as long as you have the room.



Joe

 

The Standard alternator was 61 amps.


One of the optional alternators was 85 amps. The other optional alternator was 100 amps. These are generally considered CS-130 cases.



If you have the room (been a while since I've looked at the old setups) you can look into the CS-144 cases. You'd be looking at roughly 140 amps from these guys. Try asking for a 1993 Cadillac Deville with the 4.9 engine. Will give you an idea of how big they are.


Of course, there is always the "aftermarket" alternator option. Then you can get a CS-130 case in higher amps (at higher cost too). I ran a Powermaster amp on my old 89 engine. 145 amps total output -- 95 amps at idle.



Joe

 

OK, thanks Joe, I'll look into this a little deeper.

 

http://www.naxja.org/forum/showthread.php?t=1016458

http://www.olypen.com/craigh/charge.htm