006 - Powermaster
Contents
1. ne SG f 2 fon Lo SHEET 200 AMP GM LTERNATOR Part s 48203 58203 38203 PRE INSTALLATION NOTES f your original alternator has TWO LARGE UNTHREADED mounts and an internal fan then a e Despite the larger case size this unit W L FIT in the stock brackets e The original bolts can be used for installation e Do not use the extra aluminum bushing e The bracket that mounts to the rear of the original alternator will not fit this large case unit and is not required for proper installation e The size of the charge wire from the alternator to the battery should be upgraded to a 2 4 AWG wire Internal Fan e Installation will require a plug adapter Part 160 If your original alternator has ONE LARGE UNTHREADED mount and ONE SMALLER THREADED mount then e Despite the larger case size this unit W L FIT in the stock brackets e The original bolts can be used for installation e The extra threaded aluminum bushing supplied with your new alternator should be installed in the mounting ear that corresponds to the small threaded ear on the original alternator Use a rubber mallot to carefully drive the threaded bushing in and the unthreaded bushing out Insert the bushing so that the threaded hole will be visible from the pulley side of the alternator A wrench can be used on the oversized end of the bushing to rotate the threaded hole aligning it with the hole on the vehicle s bracket e The bracket that mounts to the rea2. r of the original alternator will not fit this large case unit and is not required for proper installation e The size of the charge wire from the alternator to the battery should be upgraded to a 2 4 AWG wire e f your original unit has an internal fan then installation will require a plug adaptor Part 160 Internal Fan IVSTALLATIONINS TRUCTIONS 1 Disconnect the negative cable from the battery 2 Remove the wire harness from the original alternator 3 Remove the belt the mounting bolts and the alternator NOTE Refer to the vehicle s service manual for belt tensioner release instructions 4 install the Powermaster alternator using the mounting bolts that were removed from the old alternator Reinstall the belt and tighten the alternator bolts NOTE The original belt will work but a 1 2 inch longer belt will offer preferred belt tension J Reconnect the negative battery cable Before starting the engine make sure the battery is fully charged 12 5V or higher Do not use the alternator to charge a battery that is severely discharged 6 Start the engine Accelerate the engine to a fast idle and check the voltage It should be 14 0 14 5V at the alternator 1833 Downs Drive West Chicago IL 60185 Tech Email tech rf Tech Phone 630 849 7754 Sales Phone 630 957 4019 i a a om IS _ 48203 1 01
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