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2G to 3G Instructions 1987-1993 Mustang

1. mention and remember SAFETY FIRST Warranty note Due to tight tolerances of internal components 3G alternators are NOT to be disassembled in any way Loosening the thru bolts holding the alternator together will void the stud on the rear of the alternator using a 10mm wrench It is VERY IMPORTANT that this not be ee thet buccal a thru bolts ae dine ie Loc Tite ib nae compound over tightened as internal damage could result and void the warranty Locate the small stator plug thru bolts are installed toget a and torque is applied equally and simultaneously to ensure even and securely connect it to the new unit Finally reconnect the regulator plug disconnected in Step permanent assembly Under no circumstances are these bolts to be loosened or removed 4 18 Reconnect terminals Locate and connect BOTH large black orange stripe wires to the battery 19 Connect the battery wire disconnected in Step 1 being careful not to over tighten the bolt This would be a good time to clean any corroded battery connections or replace any cracked or damaged battery wires Since the new alternator produces more amperage corrosion may cause undue heat or prevent you from realizing the full potential of the new unit If the air box cover was 65 75 Amp 2G UPGRADED removed reinstall it now Note due to the significant increase in available power it is strongly recommended that before starting the engine with the new alternator in place you
2. continued from page 3 Common installation continued 14 Place the alternator in the vehicle Reinstall the lower mounting bolt finger tight Install the new metric top mounting bolt finger tight Do not fully tighten either bolt at this time MA Performance m sah www pa performance com e mail into pa performance com Alternator Upgrade Replacement 1987 1993 MUSTANG 5 0L ENGINE 15 Reinstall the serpentine belt in the original position removed in Step 2 We have found it easiest to install the belt on the air conditioner pulley last 16 Tighten mounting bolts With belt tension on the alternator you can now finish tightening the lower mounting bolt with a 5 8 socket and then the top mounting bolt with a 1 2 or 13mm socket Be careful not to over tighten these bolts 17 At this point stop and look at the unit wires and hoses Be sure that nothing is pinched or in The following procedure documents in exact order and detail the steps necessary to replace the OEM 2G 65 75 Amp alternators a position to be pinched Using care here will eliminate problems later with our replacement 3G 95 or 130 Amp alternator We do not guarantee that these instructions are perfect nor guarantee the results however the following instructions precisely represent this same upgrade done in our shop by our own staff As always use care in working on any vehicle take any necessary precautions you feel are needed in addition to any we
3. fastener from the rear of the unit secures wires to the alternator housing if one exists Remove the old alternator from the vehicle being careful not to snag wires or damage the car Add output terminals on the three wires cut in step 5 a Using a wire stripper strip about 1 4 of the insulation from the ends b Crimp and solder the terminals provided with the new alternator onto the ends of the large black orange stripe wires gm a gt c Crimp and solder the in line connector onto the small white black stripe wire and the white wire z z d Heat shrink tubing has been provided for all three connections and we recommend using it to ensure protection Use care not to shrink the tubing prematurely while soldering Note If you only crimp the terminals without soldering it will work but as with any electrical connection soldering is the most effective method and is what we recommend Move the mounting bushing using a small hammer or adjustable pliers to allow more room for the new alternator to fit in the opening This is a compression bushing and will snug against the new alternator when the mounting bolt is installed and tightened If you are upgrading to the 130 Amp unit add Step 13 below Because the 130 Amp unit has a larger frame than the other units the alternator mounting bracket on some vehicles will need modification If test installation of the alternator shows interference with the mounting bracket then p
4. fully charge or verify the battery 20 Start the engine Using a DC volt meter measure the voltage across the battery terminals consult the volt meter user manual for instructions if you are unfamiliar with the use of this instrument With the engine running you should be charging over 12 5 volts at idle This will assure that the alternator is charging Note In a stock application the OEM belt will work on the new 3G alternator If underdrive pulleys have been installed or if the pollution pump has been removed you will need to select a belt which keeps the tensioner in the normal position We do not recommend changing the pulley on the new 3G alternator Modifying the unit in any way changing the pulley or loosening the thru bolts will void the warranty That completes the steps we took to install our new unit If you have any questions the pictures and instructions are available on our web site and you can e mail us with any observations or questions from your own experience 6560 041201 to 95 or 130 Amp 3G Note Steps 1 to 12 and 14 to 20 apply to upgrading to both the 95 and 130 Amp units Step 13 outlines the additional modifications needed when upgrading to the 130 Amp unit Disconnect the battery negative terminal from the battery and move it to the side to prevent accidental contact during the installation Remove serpentine belt Using an 18mm socket release the tension on the belt a
5. nd remove belt from top pulleys including the alternator idler and air conditioner The tensioner is located on top and immediately to the right of the alternator You may wish to leave the belt on the other pulleys until the end so you can see the proper belt path for reinstallation If not there is typically a diagram sticker on the radiator support Remove the cover from the air filter box We found this made things easier Gently remove the regulator plug from the alternator on the car using a flat blade screwdriver This plug will be reused so be careful not to break the plastic clip continued from page 1 10 11 12 Locate the power output plug two 10 black orange stripe wires and one 14 white black stripe wire This plug typically exits on the side of the alternator closest to the air box Once you locate it cut all three wires about 2 from where they go into the plug on the alternator Remove top mounting bolt Using a 9 16 socket remove the one top mounting bolt from the alternator mounting bracket This will NOT be reused on the new alternator Remove lower mounting bolt Using a 5 8 wrench or socket remove the lower mounting bolt from the alternator mounting bracket This WILL be reused on the new alternator Wiggle the unit front to back to loosen it from the lower compression bushing This can be done by hand or with an adjustable wrench on the top mounting bracket Gently remove the wire loom
6. oner while tightening Note On all alternator upgrades Due to the significant increase in available power output you MUST upgrade the main power wire The stock wire cannot carry all of the available current safely recommended on the 95 amp kits required on the 130 amp kits PA Performance offers a complete kit
7. roceed as described below 13 Remove and modify the mounting bracket a Using a 19mm wrench remove the tensioner You will need to hold the tensioner from the front to keep the locating pin engaged and prevent the unit from spinning b Loosen and remove the top mounting bolt holding the air pump It is not necessary to remove the air pump itself c Remove the three mounting bolts holding the bracket on the engine The top and bottom bolts require a 9 16 socket while the side bolt requires a 2 socket You will need an extension and or a universal joint to access these bolts but they will come out without any hose removal etc d Mark the mounting bracket as shown in the picture and remove material in those areas with a dremel tool or grinder In some cases the lower side of the top mounting hole area will also need modification Use care when grinding to avoid getting metal fragments on the engine in the alternator or anywhere else that metal fragments should not be As always wear eye protection e Grind bracket as shown in the pictures below Test fit the alternator to ensure it does not contact the mounting bracket anywhere Always be careful not to drop the alternator on the ground which could result in permanent damage f Reinstall the mounting bracket Tighten all three bolts being careful not to over tighten g Reinstall the air oump bolt and tensioner Use care to be sure the bolt is properly seated in the tensi

2G to 3G Instructions 1987-1993 Mustang

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