Well, I installed my fancy new alternator the other day so here's a quick play by play of the wrench work. Was actually easier than I thought it would be considering where Nissan hid the damn thing.
First, remove this so you don't start an unintentional welding project/campfire.
Then remove this so you can get to the belt tensioner
Then put a 3/8 drive ratchet in the tensioner to release tension and pull the belt off of the alt and P/S side.
Then remove this
By removing these
Like this
So you can actually see this
Pull the 12mm nut off of the B+ lead on the rear, top of the stock alt (the one under the little red hat) and remove the plug next to it.
Then remove the 12mm bolt from the bottom, front right and the 14mm bolt from the top, front left and you're ready to remove the old alt. And YES, it does come out the hole with a bit of finesse!
New vs old
3 things of note:
First;
if you look at the pic above you'll see a little jumper harness in a small white box. This is needed to convert the 3 wire stock harness to 2 wire for the new alternator. Do not panic, it's supposed to be there. Just plug the jumper into the new alt and plug the other end into the stock harness.
Second;
notice the B+ stud is in a different location on the new alt. This is also by design in order to clear the new rear mounting bracket. Your stock harness should be just long enough to reach the new location. If you need a little bit of extra wiggle room you can release the clip on the main eng harness right above the alt and get a little bit of extra slack in the harness, you don't need much if any.
Third;
the new rear mounting bracket spacers were about 1mm short on mine so the alternator mounting points wouldn't quite slide over the mounting boss on the block. I fixed mine easily by removing these washers from the bolt side of the bracket here. (Steevo says he'll talk to DC Power about this btw)
And putting them under the bracket like this
Once that was done the install was mostly a reversal of the removal process with one exception.
The threaded sleeve on the 14mm alt hanger bolt is press fit into the stock alternator; you can see it here
The corresponding element on the new alternator is not press fit, it is floating. This is by design and it works fine. However, IF you live somewhere where corrosion is an issue it would be in your best interest to liberally coat the threads in the new sleeve with anti-seize at minimum and maybe even have someone tack it in place so you avoid the inevitable cursing involved when you go to remove it one day and the sleeve just spins instead of allowing the bolt to loosen. Just my .02. I added a bit of anti-seize to mine just to be safe.
So slide the new alt over the mounting boss, slide the old 14mm bolt through the front bracket, mounting boss and rear bracket, start the threads on the threaded sleeve and tighten it down through the large hole in the rear bracket until it seats against the mounting boss. Then give the lower mounting bracket a bit of a nudge, you might have to loosen it just a hair as the new alt is slightly smaller, and install the 12mm bolt. Tighten both bolts to specs.
Then plug the harness jumper into the alt and harness, wrangle the B+ lead into the new stud location, tighten it down and you're almost done.
The B+ stud on mine lined up a bit too close to the main eng harness on mine here
so I worked a tiny bit more slack into the harness to keep it clear so there would never be the possibility of the stud rubbing through into the harness (just a bit of OCD from someone with previous experience and a serious dislike of eng fires). And btw, the stock B+ wire looks to be 4ga so there is no reason to have to upgrade it believe it or not.
Once all that's done you should now be looking at this
So slap the belt back on and it'll look like this
Just make sure the belt is properly aligned on all of the pulleys before you start it up.
Then reinstall the intake tubing and neg batt cable and crank it up to make sure everything is in working order before you put the fender liner back in so you can see everything.
This is the new beast at idle with just the stereo on. It charges almost a full 1.5 volts higher at idle than the stock alt did at 2500 rpm!
And even with the dual air system running and the stereo on it still charges almost a full volt higher than the stock unit at 2500 rpm :woot:
Just a little side note; as an added bonus this bad boy cut my air up time on the 35s by over a third! Couldn't believe how fast the OBA aired the tires back up yesterday after the trail run! Awesome ::grin::
Well there you have it. I'm pretty happy with the purchase all things considered. Yes, it's a SPENDY little piece of shiny, new tech but considering the stock replacement is even more expensive it's tough find a reason NOT to upgrade, especially if your stock unit is failing. This little beauty puts out more amperage at idle than the stock Pro-4/SL alt at max output!
Feel free to hit me up with any questions and let me know if anyone would be interested in me making this a stand-alone DIY thread for future reference.