Charging issues with Toyota style Denso Alternator
Update:
I received the new pulley and quickly realized I had a problem. The OD of the recessed area (where the flanged nut sits) on the new pulley is a little over 29mm. With the 22mm pulley nut that came with the alternator, all of my 22mm sockets were too large too fit inside the recessed area
Original vs. new pulley
OD of Craftsmen 22mm Socket
New pulley installed with original 22mm nut (hand tightened only)
After a long internet search I came across a fastener supply site that carried a 19mm nut to fit the 14x1.5mm alternator shaft. A 19mm socket was small enough to fit inside the recessed area and actually tighten the nut.
New pulley installed with new 19mm nut (torqued)
Finally reinstalled everything and its now charging between 13.5-13.8 volts at idle speed and 14.2 at a fast idle. Not great at idle but certainly much better than before the alt pulley swap.
I'm going to see how the car performs driving around town and at stop lights and make a decision on whether I need to consider going back to the stock diameter pulleys (crank/water pump).
Update:
I received the new pulley and quickly realized I had a problem. The OD of the recessed area (where the flanged nut sits) on the new pulley is a little over 29mm. With the 22mm pulley nut that came with the alternator, all of my 22mm sockets were too large too fit inside the recessed area
Original vs. new pulley
OD of Craftsmen 22mm Socket
New pulley installed with original 22mm nut (hand tightened only)
After a long internet search I came across a fastener supply site that carried a 19mm nut to fit the 14x1.5mm alternator shaft. A 19mm socket was small enough to fit inside the recessed area and actually tighten the nut.
New pulley installed with new 19mm nut (torqued)
Finally reinstalled everything and its now charging between 13.5-13.8 volts at idle speed and 14.2 at a fast idle. Not great at idle but certainly much better than before the alt pulley swap.
I'm going to see how the car performs driving around town and at stop lights and make a decision on whether I need to consider going back to the stock diameter pulleys (crank/water pump).
