XJ6 series 1 alternator swap
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Member
Joined: Feb 2016
Posts: 90
Likes: 31
From: Illinois
XJ6 series 1 alternator swap
Happy New Year everyone!
On my wife's 1971 xj6, we diagnosed alternator problems: either charging normal, overcharging, and leaving a headache rendering sulphor smell from the battery.
The car has factory a/c (York comp.), which means a Butec alternator with an external voltage regulator.
Rather than spend crazy money on replacing either or, or both, opted for a GM/Delco "one wire" alternator.
The alternator is mounted above the a/c compressor and there is no air pump. So after tons of research, I dove in.
I purchased the alternator from NAPA for $64, which includes a lifetime warranty! The only other part needed was an off the shelf Mr Gasket Chevy universal alternator bracket, $15.
First, disconnect the battery, remove the three wires from the alternator, main positive and two fields, the ground strap, and disconnect the plug from the external voltage regulator. Unbolt the alternator, one upper long bolt, and the bottom bracket is integrated into the alternator housing, but has a long threaded tension rod assembly, remove this.
The upper alternator bracket fits the new alternator, but requires one modification, you have to cut out the center bolt tube. A cutting disc does this in a couple of minutes. The factory bolt will be reused. Next, where the lower tension rod was, place your Mr Gasket bracket there, upside-down using the inner mounting hole (of the two), so the curvature goes underneath the alternator to cradle it.
The new alternator comes the lower adjustment bolt already, so one less thing to buy! You will need spacers for the upper bolt and bracket (3/8" hole and 1 3/4" long approximately, but this will vary).
Place the alternator in the upper bracket, insert the factory bolt (along with the spacers), and finger tighten the nut. Next, insert the included new alternator bolt into the new bracket. Put in place your new alternator belt and tighten. I used a NAPA 25-7405.
From the original alternator, remove the factory positive "L" bracket wire plug, and put it on the new alternator positive brass bolt. Plug in the positive wire, tape off and tie up all other non used wiring, reconnect your battery, and YAY!
If you have any questions or comments, please feel free to ask. And yes, I have removed the ground strap since the last photo.
On my wife's 1971 xj6, we diagnosed alternator problems: either charging normal, overcharging, and leaving a headache rendering sulphor smell from the battery.
The car has factory a/c (York comp.), which means a Butec alternator with an external voltage regulator.
Rather than spend crazy money on replacing either or, or both, opted for a GM/Delco "one wire" alternator.
The alternator is mounted above the a/c compressor and there is no air pump. So after tons of research, I dove in.
I purchased the alternator from NAPA for $64, which includes a lifetime warranty! The only other part needed was an off the shelf Mr Gasket Chevy universal alternator bracket, $15.
First, disconnect the battery, remove the three wires from the alternator, main positive and two fields, the ground strap, and disconnect the plug from the external voltage regulator. Unbolt the alternator, one upper long bolt, and the bottom bracket is integrated into the alternator housing, but has a long threaded tension rod assembly, remove this.
The upper alternator bracket fits the new alternator, but requires one modification, you have to cut out the center bolt tube. A cutting disc does this in a couple of minutes. The factory bolt will be reused. Next, where the lower tension rod was, place your Mr Gasket bracket there, upside-down using the inner mounting hole (of the two), so the curvature goes underneath the alternator to cradle it.
The new alternator comes the lower adjustment bolt already, so one less thing to buy! You will need spacers for the upper bolt and bracket (3/8" hole and 1 3/4" long approximately, but this will vary).
Place the alternator in the upper bracket, insert the factory bolt (along with the spacers), and finger tighten the nut. Next, insert the included new alternator bolt into the new bracket. Put in place your new alternator belt and tighten. I used a NAPA 25-7405.
From the original alternator, remove the factory positive "L" bracket wire plug, and put it on the new alternator positive brass bolt. Plug in the positive wire, tape off and tie up all other non used wiring, reconnect your battery, and YAY!
If you have any questions or comments, please feel free to ask. And yes, I have removed the ground strap since the last photo.
Thread Starter
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Member
Joined: Feb 2016
Posts: 90
Likes: 31
From: Illinois
Here are the photos.
/Users/rsq911/Desktop/IMG_3487.jpg
/Users/rsq911/Desktop/IMG_3495.jpg
/Users/rsq911/Desktop/IMG_3488.JPG
/Users/rsq911/Desktop/IMG_3506.JPG
/Users/rsq911/Desktop/mrg-9851_ml.jpg
/Users/rsq911/Desktop/IMG_3507.jpg
/Users/rsq911/Desktop/IMG_3487.jpg
/Users/rsq911/Desktop/IMG_3495.jpg
/Users/rsq911/Desktop/IMG_3488.JPG
/Users/rsq911/Desktop/IMG_3506.JPG
/Users/rsq911/Desktop/mrg-9851_ml.jpg
/Users/rsq911/Desktop/IMG_3507.jpg
Last edited by rsq911; Jan 6, 2017 at 06:58 PM.
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Joined: Jul 2012
Posts: 6,796
Likes: 2,403
From: Walnut Creek, California
Nice work. All that needs to be said.
Although, I do like the elegance of the tension rod method of belt tension adjustment over the simple slotted arm. But, each does the job....
Carl
Although, I do like the elegance of the tension rod method of belt tension adjustment over the simple slotted arm. But, each does the job....
Carl