Hi All,
The external regulator for my D shit itself a while back and in the process of sorting it out ( I posted a thread here), I decided rather than persist with external reg setup I would go with a new alt with internal reg. I found little info about to help, I saw some stuff from Richo on his conversion for another frogger, I think he used a Denso alt? But it would appear they are no longer supplied in Australia.
For the benefit of others I thought I should document what I did in case someone else wants to do it. This mod suits me, I'm not suggesting others should venture from original, and my set up can be reversed as I have all the original parts etc and the new loom is not modified.
I chose a Bosch alt, 70 amps, I had to source a twin pulley separately, as the original alt has a longer shaft, both are 17mm dia shafts, the new one is slightly larger dia, about 75mm dia vs 55mm ish for the older one.
Because its a Citroen it has the weird bracket that it mounts onto, this leaves a space for the metal radiator pipe to pass under the alt, this causes an issue as most alts have a deeper mounting lug on the bottom. I didn't want to cut this down as it left little meat, also wanted to keep it a straight swap to replace if that ever happened.
Also as the alt pivots on the lug and bolt, the original has 3 bolts that go into the alt body at the rear to hold it straight.
Could not find a new alt that had this fixture. The other consideration was the clocking of the bolt hole for the tension bracket, so just picked one with it at the top.
So to make it fit I had to fabricate a new bracket to replace the original.
To that end I made up a jig that replicated the mount from the engine.
Then by mounting the old alt, I made some adjustable points that a straight edge could be used to mark the orientation of the alternator to the other pulleys.
Then with the new alt in its place I could fab up the bracket to the mirrored mount and true it up with the guides ( with adjustments for the differences in the pulleys)
So the new bracket keeps the clearance below the bracket for the radiator pipe, plus about 5mm extra, so the alt sits about 20mm higher.
To stop the rotation, I removed the bottom 2 long screws that hold the body of the alt together and replaced it with threaded rod and nylox nuts, that fit into my bracket at the back.
Here it is in place in the car, good clearance under for the radiator pipe, looks the same as before, I did have to make a new tension bracket for the top to clear the alternator, so that is visually different. The belts had to be replaced they are 25mm longer in overall length( now 11A1005 )
The brackets are getting a lick of paint now and it will go back in tomorrow, then attaching wires and looking forward to having a dash charge light again which I didn't have with the old reg I had (Bosch RE055?)
Thanks to those forum members who helped out with info etc, in my previous posts about alternators and pulleys.
cheers
Steve
The external regulator for my D shit itself a while back and in the process of sorting it out ( I posted a thread here), I decided rather than persist with external reg setup I would go with a new alt with internal reg. I found little info about to help, I saw some stuff from Richo on his conversion for another frogger, I think he used a Denso alt? But it would appear they are no longer supplied in Australia.
For the benefit of others I thought I should document what I did in case someone else wants to do it. This mod suits me, I'm not suggesting others should venture from original, and my set up can be reversed as I have all the original parts etc and the new loom is not modified.
I chose a Bosch alt, 70 amps, I had to source a twin pulley separately, as the original alt has a longer shaft, both are 17mm dia shafts, the new one is slightly larger dia, about 75mm dia vs 55mm ish for the older one.
Because its a Citroen it has the weird bracket that it mounts onto, this leaves a space for the metal radiator pipe to pass under the alt, this causes an issue as most alts have a deeper mounting lug on the bottom. I didn't want to cut this down as it left little meat, also wanted to keep it a straight swap to replace if that ever happened.
Also as the alt pivots on the lug and bolt, the original has 3 bolts that go into the alt body at the rear to hold it straight.
Could not find a new alt that had this fixture. The other consideration was the clocking of the bolt hole for the tension bracket, so just picked one with it at the top.
So to make it fit I had to fabricate a new bracket to replace the original.
To that end I made up a jig that replicated the mount from the engine.
Then by mounting the old alt, I made some adjustable points that a straight edge could be used to mark the orientation of the alternator to the other pulleys.
Then with the new alt in its place I could fab up the bracket to the mirrored mount and true it up with the guides ( with adjustments for the differences in the pulleys)
So the new bracket keeps the clearance below the bracket for the radiator pipe, plus about 5mm extra, so the alt sits about 20mm higher.
To stop the rotation, I removed the bottom 2 long screws that hold the body of the alt together and replaced it with threaded rod and nylox nuts, that fit into my bracket at the back.
Here it is in place in the car, good clearance under for the radiator pipe, looks the same as before, I did have to make a new tension bracket for the top to clear the alternator, so that is visually different. The belts had to be replaced they are 25mm longer in overall length( now 11A1005 )
The brackets are getting a lick of paint now and it will go back in tomorrow, then attaching wires and looking forward to having a dash charge light again which I didn't have with the old reg I had (Bosch RE055?)
Thanks to those forum members who helped out with info etc, in my previous posts about alternators and pulleys.
cheers
Steve
