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Saturn Alternator swap

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56K views 79 replies 40 participants last post by  Snot Rocket  
#1 ·
I have fought with DSM alternators for years and I'm sick of the $120+ cost of replacing a weak 65amp stock unit. There are rewound units that put out 105 and 135amps but at a cost of $175-$250 I say no thank you. If you have a few basic tools a a little bit of time here is your answer.

Thanks to my local pull-a-part this swap cost me a tad over $26! :D
These saturn alternators can be had brand new with a lifetime warranty for about $70.

Tools needed:

basic hand tools: wrenchs and sockets
small grinder or dremel
soldering iron

Parts needed:

Saturn Alternator from a 93-99 Saturn 1.9L dohc ( 1996 Saturn SC2 dohc )

I did the mock-up on a spare motor and have also done this on my car. It took about 30 minutes using a dremel.

The benefit is a more powerful and CHEAPER alternator.

Saturn, meet Mitsubishi:
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The alternator needs to be clearanced to allow it to rotate to be tensioned.
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Grinding

more grinding

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Grind "A" to match "B"
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Grinding

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You retain the stock bracket and tensioner. Flip the tensioner to clear the fan blades. You will also need a longer bolt with a nut and lock washer to attach the tensioner to the alternator since the saturn unit is not threaded like the stock DSM alt.
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Wiring is pretty straight forward, the large yellow wire goes to the F(black) wire on the saturn connector and the small black wire goes to the L(black w/ white stripe) on the saturn connector.
 
#3 ·
oops, i thought i put that in there.. they are rated at 95-105 amps. Quite a step up over the stock 65 amps.
 
#9 ·
Dude, You are a genius! This is an awesome find. I have to ask....How the Hell did you think about this? And out of all cars, how did you choose a Saturn to get this alternater from.
The fan blade is a huge plus on this alternator design as it will keep it running cooler since the manifold is right there! This should be a Sticky or better yet included in the Vfaq archives.
 
#13 ·
4G63 POWER said:
Oh man so janky,, whats wrong with a gvr4 alternator ??
All mitsu alternators for dsms and gvr4s use the same POS regulator, which is normally the problem.
 
#15 ·
Chicago1 said:
Do the relocation kits work with this?
The Jay racing kit will not unlees you fab up an extension to bolt to the ear on the alt.
 
#16 ·
4G63 POWER said:
So this regulator is different ? The heat is the problem not the regulator. The gvr4 alternator is a bolt on & 90amp iirc.
The gvr4 unit is 95amps and is bolt on. It also cost ~$120+ and still has the same inability to maintain steady output under high load situations.

Also the fan on the saturn alt moves air across the alt from the driver side to the pass, whereas the mitsu units internal fans sucks in hot air right off the downpipe.
 
#18 ·
b00st3d said:
The gvr4 unit is 95amps and is bolt on. It also cost ~$120+ and still has the same inability to maintain steady output under high load situations.

Also the fan on the saturn alt moves air across the alt from the driver side to the pass, whereas the mitsu units internal fans sucks in hot air right off the downpipe.
VR4 alt is 90 amps. I have a lifetime warranty one in my car for the longest of any alt my car has ever had. $103. Still no evidence of any issues with it yet. I went through 4 of the pos 75 amp alts in less than a year.
 
#19 ·
b00st3d said:
The gvr4 unit is 95amps and is bolt on. It also cost ~$120+ and still has the same inability to maintain steady output under high load situations.

Also the fan on the saturn alt moves air across the alt from the driver side to the pass, whereas the mitsu units internal fans sucks in hot air right off the downpipe.

Yes new it does. How much does a new saturn alternator cost ? I thought you were putting in used not new. A used gvr4 would cost you the same as the used saturn.

Not sure where you are getting your facts about the gvr4's abilities, but a vr4 has more accesories etc.. to run than a dsm. Judging by your pics of your engine you have way more important things to worry about then alternators. I'm sure your maxing out gvr4 alternators with your setup. I have seen no proof of your claim.

You wouldn't have to worry about heat from your downpipe if you had a heat shield installed.
 
#20 ·
#21 ·
4G63 POWER said:
Yes new it does. How much does a new saturn alternator cost ? I thought you were putting in used not new. A used gvr4 would cost you the same as the used saturn.

Not sure where you are getting your facts about the gvr4's abilities, but a vr4 has more accesories etc.. to run than a dsm. Judging by your pics of your engine you have way more important things to worry about then alternators. I'm sure your maxing out gvr4 alternators with your setup. I have seen no proof of your claim.

You wouldn't have to worry about heat from your downpipe if you had a heat shield installed.
So because i used a spare motor that is dirty to do the initial mock-up it somehow makes this less effective? :rolleyes:

The saturn alternator is $70 NEW with a lifetime warranty, the gvr4 alt IS $120+ NEW.

As for my downpipe, it is wrapped in two layers of exhaust wrap, but thanks for your concern.
 
#23 ·
4G63 POWER said:
Judging by your pics of your engine you have way more important things to worry about then alternators. I'm sure your maxing out gvr4 alternators with your setup. I have seen no proof of your claim.

You wouldn't have to worry about heat from your downpipe if you had a heat shield installed.
That's really uncalled for. He said early on it was a spare engine. An apology would be in order.
 
#24 ·
tarantula said:
Dude, You are a genius! This is an awesome find. I have to ask....How the Hell did you think about this? And out of all cars, how did you choose a Saturn to get this alternater from.
The fan blade is a huge plus on this alternator design as it will keep it running cooler since the manifold is right there! This should be a Sticky or better yet included in the Vfaq archives.
The idea to find a better solution was that of a felow dsmer here in the city who owns a car lot. He found that the saturn alt was similar and could be made to fit with a little work, all I did was implement it and document what needed to be done to make it happen.