Changes to Step #4
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Edit approved by Hybrid Racing
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[* 1] To reinstall the alternator, first the supplied alternator bracket (as shown on the right in Figure 3a) must be installed. The bracket bolts up to the same two (2) holes the original A/C bracket bolted to (see Figure 3b). Use the 2 supplied black M10x1.25 bolts. | |
[* 1] The bolts can be tightened with an 8 mm or 5/16” allen driver. Do not fully tighten the M10 bolts until after the alternator has been installed. This will aid in properly aligning the lower two (2) holes in the alternator with the threaded holes in the alternator bracket. | |
[* 1] Once the alternator bracket has been bolted up, begin mounting the alternator by inserting the supplied 100 mm M8x1.25 bolt through the upper alternator mounting hole. Use n 6 mm allen wrench to tighten this bolt. This bolt should thread into the block where the top left mounting bolt for the A/C compressor originally went (as shown in Figure 3c). | |
+ | [* 1] The supplied tall black spacer should be fitted between the alternator and the engine block as shown in Figure 3c. Thread the bolt fully in but do not tighten until the lower two (2) bolts have also been installed. |
+ | [* 1] Next, affix the lower two (2) alternator mounting points to the alternator bracket as shown in Figure 3d. Some applications may require the use of the two (2) supplied short, black spacers between the alternator and bracket as shown in Figure 3e. |
+ | [* 1] There are two (2) different flange thicknesses on K-series alternator for the lower two mounting bolts. If you have a 30 mm (1.18in) flange, use the supplied 55 mm M8x1.25 bolts. If you have a 40 mm (1.57in) flange, use the supplier 65 mm M8x1.25 bolts. See the table below to see if you should use them. |
+ | [* 1] DO NOT use the lower spacers if your application does not require them. After all 3 alternator mounting bolts have been installed, first tighten all 3 alternator mounting bolts. Finally, tighten the 2 black alternator bracket mounting bolts. For best results, use a ballnose 8 mm or 5/16” allen wrench as shown in Figure 3f. |
+ | [* 1] Torque all three M8 bolts to 35 lb-ft (dry) or 28 lb-ft (lubricated with oil). Torque both M10 bolts to 70 lb-ft (dry) or 55 lb-ft (lubricated with oil); a swivel joint is needed to access and properly torque these M10 bolts. Failure to properly torque bolts can result in premature fatigue or loosening of the bolts. (Note: color of bolts may vary) |