100amp alternator upgrade for 200tdi Defender engines

Napalm00

Technical Excellence Contributor
Ive been searching high and low for a alternator that would fit in the stock location, work with Vbelt, have a idiot light sender and a "W" or tach output.

After seeing that bripart makes a 100amp upgrade for this and the disco 200tdi I was deadset on finding out where they sourced this alternator from to save on shipping and retail.

LOOOONG story short you can use a 1993-1995 Range Rover 4.2 aka vogue alternator, with very minor modification.

Bingo 100AMPS!!!!!!


Materials Required:

Alternator: LR# YLE10100, Remy 14362, Marelli 54022470 or equivalent
https://www.amazon.com/gp/product/B00BTJM9TG/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1
Five feet of 4 gauge stranded primary wire
two 4 gauge heavy duty ring terminals/lugs
one 12awg-14 ring terminal
One washer about 8mm ID (whatever you have laying around)
Your old alternator
Some heatshrink or electrical tape

Materials possibly required:

New slightly longer V belt (depending on alt pulley diameter)
I used a Gates #7405 10mmx1044mm


Tools

Assorted metric sockets
Pry bar
crimper or vise
Lighter or heat gun
Voltmeter
8mm allen key
Impact gun

How To:

  1. Disconnect battery
  2. remove fan shroud if equipped
  3. remove intercooler pipes
  4. remove mounting bolts on old alt
  5. remove old alt
  6. remove nut on the starter solenoid hot side with cable going to battery
  7. remove engine wiring harness (mark the water, oil and IP pump connections)
  8. remove old shitty brown wire from harness that went from the old alt to the starter solenoid
  9. using old shitty wire for length estimation make a 4g power wire with HD lugs on both sides (make sure to check that they fit on studs on new alt and starter, dill out if needed)
  10. tape up or heatshrink the engine harness and reinstall all connections
  11. run new 4g cable from where new alt will be to the starter following engine harness
  12. Using impact gun or a wrench and allen key remove V belt pulley from old alt, remove flat spacer and set aside, remove external fan and set aside, remove the spacer closest to the alt bearing and put aside
  13. remove serp belt pulley with impact or wrench and allen key from new alt
  14. using spacers removed from old alt (depending on what you have a trip tot hardware store for washers or spacers may be needed , mine bolted right up) install the v belt pulley on the new alt
  15. mock up the new alt on the engine to make sure that the Vbelt pulleys are parallel to one another and the the belt wont be running on a crazy angle
  16. using a dab or grease or glue stick the random washer from the parts list above to the new alt bottom rear foot on the inside
  17. This is needed because the stock alt has a 80mm mounting spacing for the bottom feet and the new alt has 83mm so we are taking up that space (FYI the britpart kit does the same exact thing)
  18. Loosely bolt up the new alt
  19. Connect the new charge 4g battery cable to the large stud on the new alt marked B+
  20. cut off the stock spade on the brown with white stripe smaller wire that also ran to your old alt and replace it with the small ring terminal from the parts list
  21. install this smaller wire to the middle stud on the alt marked D+
  22. If you have a tach wire (white is stock color) connect this the last stud marked "W"; disregard if you dont have this
  23. reinstall all the wiring to the starter solenoid, making sure that you put the spade connection on there as well
  24. tighten your alt belt using the pry bar to get it snug
  25. reinstall fan shroud and intercooler pipes
  26. reconnect battery cable
  27. start truck
  28. check voltage at battery (should be more than 13.5v)
  29. Done



stick alt measurements pic by Miles
 

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RDavisinVA

Technical Excellence Contributor
Great work...
The only issue could be that 100 AMPs is pushing the ability of a single V-Belt to handle that much load, so keep an eye on the belt and carry a spare with you along with the wrenches to install it just in case.
If you hear the belt squeeling tighten up the adjustment ASAP to keep the belt from wearing out.
If you plan to run an inverter or other equipment that will draw a lot of power, look into a dual V-belt setup with a custom pulley.
It's possible to fit a dual belt water pump and alternator pulley and still have enough room for the PS pump pulley on that engine.
 

Napalm00

Technical Excellence Contributor
After about a year of usage it seems to be working great! Definitely keep an eye on the belt tension.

the great thing about this alternator is that it automatically starts charging as soon as the truck turns on it doesn't require a little blip in throttle.

I run mine with a really really tiny v belt pulley that I pulled off of a 2.5 na alternator.
 
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