130 (or 150) Extra Amps on a 2F

Godwin · 05-20-08, 08:35 PM

Over a year ago I rebuilt the 2F in my FJ60 and at the time I had planned on installing a second alternator in place of the smog pump. I first tried to mount a Delco CS-144 (http://forum.ih8mud.com/60-series-wa...nstall-2f.html), and later tried a CS-130 with essentially the same results. Since the alternator will be needed to drive the water pump I wanted an installation that was simple, reliable, and if possible could be uninstalled and reverted back to stock easily.

A couple of threads in the 80 series forum (http://forum.ih8mud.com/80-series-te...r-upgrade.html and http://forum.ih8mud.com/80-series-te...0-150-amp.html) lead me to look at the Toyota 130 (150) amp alternator. 2003-2007 Sequoias have a 130 or 150 amp alternator, PN’s 27060-0F040 and 27060-0F050 respectively. Some V8 Tundras have a 130 amp alternator. I went with a 2003 Tundra V8 130 amp alternator, PN 27060-50300, and hit a small snag with it (explained here http://forum.ih8mud.com/80-series-te...lternator.html).

The alternator is slightly smaller than the smog pump. The upper and lower mounts are in nearly identical positions, but the spacing on the alternator is slightly smaller. For the install I used the stock 2F smog pump bracketry. The slot in the upper mount had to be slightly enlarged to accommodate the slightly closer spacing between the upper and lower alternator mounts. A dremel easily took care of this.

Godwin · 05-20-08, 08:36 PM

The upper smog pump mount has a long sleeve and the tensioning bolt had to be spaced back ca. 25 mm so that it could be used to tighten the alternator. A spacer was cut from some flat stock for this.

Inner diameter of both the upper and lower mounts on the alternator is 10.5 mm. Diameter of the smog pump mounting bolt is 7.8 mm. I used sections of ½” copper tubing as sleeves in the smog pump mounts to fill some of the gap.

Three copper sleeves were cut:
1) 54.5 mm long, to fit in the lower alternator mount;
2) 47.5 mm long with a large washer JB welded on. This holds the alternator in place;
3) A 35 mm long sleeve to fill the upper mount.

Godwin · 05-20-08, 08:38 PM

The alternators have a pulley for a serpentine belt, but a V groove pulley can be swapped on (PN 27411-66040). This is a double groove pulley and ½ of the front pulley will have to be cut off.

Width of the alternator pulley at the outer edge is 9 mm and depth is 11.5, width on the smog pump pulley is 15.5 mm and depth is 15.5 mm. Stock belt is 16 mm wide. I went to Carquest with a cut down belt as a reference and requested a belt of the length I brought in but slightly smaller in width. I was looking for a compromise in width between the pulleys, but at the time I did not have the width measurements. What I came back with was a Carquest belt B40 manufactured by Gates. It is 43” long x 21/32” wide, or 1085 mm long and 16 mm wide. This belt is the same width as stock. I mounted it anyway and so far there’s been no problem.

To plug in wires this connector is needed (PN 90980-11964), this will only be the plastic shell and wires have to be added. I was able to scavenge some terminals from damaged harnesses from the local Toyota dealership, but if wiring terminals need to be purchased this is the PN 82998-12440. Three will be needed.

Godwin · 05-20-08, 08:40 PM

I had tried to scavenge terminals from an FJ60 harness by using the smallest terminals of the harness. These were too large to fit the connector shell. From the later model harnesses at the Toyota dealership I pulled two sizes which I’ll call “larger” and “smaller”. For reference I’ll give the dimensions of the terminals as w(idth) x h(eight) x l(enght) in mm.

FJ60 4.01 x 2.68 x 5.16
Larger 3.08 x 2.76x 9.02
Smaller 2.57 x 2.51 x 7.05

While the smaller terminals had a tighter fit on the alternator pins once in the connector they did not have a depth I was comfortable with, so I swapped those out for the larger terminals. I think these will provide a greater contact area because they are 2 mm longer.

In the photo the FJ60 terminal is on the left, the “larger” late model center, and the “smaller” on the right.

Godwin · 05-20-08, 08:41 PM

It’s been mounted and briefly tested and the belt alignment is good and there is no interference with the belt running the 2F alternator and power steering pump. This setup allows a reversion to the smog pump if needed by simply swapping out the parts.

I still need to install the second battery tray, battery, move the overflow bottle and wire everything up.

PhilC64 · 05-20-08, 10:23 PM

Excellent thread! Keep up the amazing work! I need to do something like this to my 3FE! You can never have enough power in these things!

Godwin · 05-24-08, 08:51 PM

I got around to hooking up the wires this weekend. First step was to relocate the overflow bottle. An unused threaded hole on the passenger side fender worked out well.

A second stainless battery tray was installed on the driver's side where I dropped in a Yellowtop group 31 Optima. The winch was hooked to this battery.

It was a bit of a squeeze but I was able to route the intake hose around to the fender and plug it into one of the unused holes.

The actual wiring of the alternator was straightforward. The IG wire went to a source which has 12 v when the ignition is on. The S, sensing, wire was connected at the + battery terminal. I had hoped that the L, idiot light, terminal could be used to run a voltmeter but this did not work.

For the battery ground I used some 1/0 cable I had on hand and ran a ground to the frame and from the driver's side motor mount to the frame. A 4 gauge cable runs from the B post on the alternator to the + battery terminal.

Godwin · 05-24-08, 09:07 PM

I've also hooked up an ammeter and voltmeter to keep an eye on things. So far I've put about 250 miles on this setup with no problems. Long term who knows?