I just installed a GM 78 amp alternator kit, on my 1.3 L. Its was a very simple install even with all the grinding that is required. There are several companies that you can purchase an entire kit from or you can buy it in pieces and put your own kit together. Which ever way you decided to go you will need a new alternator (mine was an autolight, 7127M A7127M), an alternator pigtail, a new lower bracket for the larger alternator and a new belt.
Now you will need to remove the old alternator from your engine, saving the upper bracket to be used with the new alternator.
When comparing the new alternator to the old, it looks like it will be a tight squeeze but well worth it if you are running any off road light or a winch all from the original battery and alternator. This is even a good install if you can hear you motor kit down when you turn on your lights!
Now install the new lower bracket and tighten it down, then place the new alternator on the lower bracket and then you are ready to start modifying the upper bracket to make it fit with the larger alternator.
Now it is time to modify the upper bracket, I first intended to take the picture of the upper bracket and put into photoshop to show where the grinding needs to accrue. After I had to grind on the bottom of the bracket and grind back the slot that holds the tension on the alternator, I thought it would just be to confusing. So just grind a little at a time until the bracket fits. I only hope you have better tools to work with than a 4 ? angle grinder and a dremel tool as I did.
Once you have the upper bracket ready to fit, hook up the belt and then you need to reconnect the wire with a loop connection to the back of the alternator. Then you are left with the task of cutting off the stock connector that plugged into the alternator and connecting it to the pigtail. Don't make the mistake of thinking red goes to red and black to black. Because I found that the colors will hook to the opposite color. A sure fire way to make sure of a proper connection is to start the motor then shut it off. If the motor stops running you hooked up right. If the motor keeps running you need to switch you wires.
I hope this makes installing a larger alternator easier for some of you.
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