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AC Delco/GM Alternator Swap Part 2 - CS144 Installation

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Nigel    5

Update:

 

I've had my CS-144 alternator in my Z for just over a year and less than 10K miles now. It was working fine up until a few weeks ago. I started to hear an occasional rattling sound coming from somewhere near the front of the car when the engine was idling. At first they were brief rattles, that would just last for an instant and sounded something like a loose exhaust heat shield. But it quickly became more persistent, to the point that it would often be a constant, loud, whirring, rattling noise any time the engine was idling. However, to complicate matters, sometimes there would be no noise at all, like everything was fine. Or, it would start out noisy, and then just go away.

 

My initial fear was that it was the timing chain. If I had to imagine what a loose timing chain would sound like, this would be it, and the sound was coming from the very front of the engine. But with the use of a stethoscope, it was determined that the sound was actually coming from the alternator. After removing the belt, and turning the alternator by hand it was easy to hear and feel that the alternator fan was rubbing on the housing. But why?

 

The rotor in the later model of these alternators is bolted to the inner race of a ball bearing that has the outer race pressed into the front housing of the alternator and provides the main support for the rotor. At the rear is a small needle bearing that the other end of the rotor sits in. Other than the press fit of the ball bearing in the housing, there is nothing securing the rotor axially in the alternator. As I was told by a reputable alternator repair shop, sometimes the ball bearing will work itself loose in the housing, and the rotor will gradually move back in the alternator until parts start rubbing. If this happens, the housing is junk, and there's no point in reusing it. It will just keep happening. If you didn't do anything about it, I'm sure the alternator would eventually seize right up. Earlier versions had a plate that secured the bearing in the housing to prevent this. So much for progress...

 

Here's an exploded view of the later version of the CS-144 alternator...

 

DR-CS144_Late_exp_view.jpg

 

Hopefully posting this will reduce the troubleshooting time for someone in the future.

 

Nigel

Edited by Nigel

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Nigel    5

Update #2

 

I've just had a second alternator fail due to the ball bearing coming loose in the front housing! There is a snap in retainer available (part number 46-1509 in the exploded view I provided in my previous post), but neither the OEM or rebuilt CS144 alternators I've had have one. I'm going to try to get one, and hopefully salvage the alternator I have now. It's only a $2 part. I'd advise anyone doing this swap to install one.

 

Nigel

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Nigel    5

Here's a picture of the inside of the front housing after the bearing had worked itself part way out:

 

20130915_205043.jpg

 

I stopped by a local alternator repair shop and they gave me the snap-on bearing clip for free! (Thank you R&D Auto Electric in Brampton, Ontario!)

 

20130916_174454.jpg

 

Nigel

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tamo3    0

It was so hard to remove pulley.

I followed this step to try to remove pulley.

http://www.ifsja.org/forums/vb/showthread.php?t=131960

 

post-25175-0-81994100-1413004291_thumb.jpg

I don't know how much I need to bang hammer with 27mm socket.

 

I try to use impact gun to try to remove the tapered collar.

post-25175-0-00255300-1413004412_thumb.jpg

No luck to remove the collar.

 

I decided to cut it off.

post-25175-0-30982700-1413004454_thumb.jpg

post-25175-0-24384800-1413004466_thumb.jpg

post-25175-0-12026300-1413004475_thumb.jpg

 

Once the collar comes out, pulley fell off!

post-25175-0-15108100-1413004485_thumb.jpg

 

Once the pulley is out you may now get very excited and start telling your wife all about how awesome you are. When it becomes clear that she simply does not appreciate just how awesome you are, proceed to next step .....

 

 

 

 

 

 

 

 

 

post-25175-0-04836800-1413004721_thumb.jpg

Beer!

Edited by tamo3

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HuD 91gt    2

Alternator gurus please help.

 

Purchased this 1994 Cadillac Seville Alternator to do a conversion on my 240z.

 

The alternator looks almost identical to the one in this thread, but it has the connector on the side, with 3 individual connectors. This bunch of wires does not let the alternator twist in it's mount to adjust.

 

Does anyone know what these are? I tried removing the connector, but can't seem to open the alternator. Also the connector which which holds the sense wire has 4 wrongs, from this thread it seems the others have 2?

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HuD 91gt    2

Pictures




EDIT:   Further investigation shows that I purchased an alternator for a Cadi with a heated windshield.   The 3 wires coming off the alternator are an AC output for the windshield.  This version of alternator also has one extra prong.

Let's hope I can dissemble the casing, and reclock the ALT so the connection is on the other side and gives me a little more room.

post-44040-0-57451700-1477004030_thumb.jpg

post-44040-0-49575200-1477004050_thumb.jpg

Edited by HuD 91gt

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HuD 91gt    2

Well, after some research I disassembled the alternator, removed the AC wires, clocked the alternator over 90 degrees and put it all together.

 

On my '71 240 I purchased the msa converted for an internally regulated alternator. I attached the 12v constant yellow to S "sense" output. I then attached the switched 12v wire to F "field" prong.

 

I'm not getting any charge at all. The later 280z had a discharge light. Is this used as the exciter? I don't believe a 240z has this. Do I require a resistor?

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hansonsaid    0

i'm in process on this swap right now, and have a question:

 

my nissan/hitachi pulley is badly worn, and i'd like to use a new v-belt pulley on the cs144.  there are plenty of 2" diameter options, but should i be using a 3/8" or 5/8" WIDTH pulley?  it's hard to measure based on my stock nissan pulley, and the brand new, nissan oem belt is almost exactly 1/2" wide.

 

any experience/opinions?

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