Alternator Bracket Kits for Denso and Powermaster Alternators

AR Engineering produces a line of alternator brackets designed to adapt several popular "mini" alternators to both big and small block Mopar engines. Weight savings of up to 10 pounds can be gained by switching to a modern Denso alternator. Not only do you save weight, but since the Denso alternators are internally regulated, you can simplify the wiring harness on your Mopar by eliminating the firewall mounted voltage regulator. Super lightweight kits using the small Powermaster 8162/8172 alternators are also available.

Race Kits using the super lightweight Powermaster 8162/8172 alternator

AR209 Big Block Race Kit – Adapts the super-lightweight Powermaster 8162 or 8172 alternator to any RB engine using the 1967 or newer water pump housing. If you have an early water pump housing then you will need to substitute the OEM early upper bracket for the bracket in this kit. The 8172 produces 50 amps. Information on this Powermaster alternator can be obtained at www.powermastermotorsports.com.

AR209H Hemi Race Kit – Adapts the same Powermaster 8162 or 8172 alternators to the 426 Hemi engine.

AR096 Small Block Race Kit – Adapts the Powermaster 8162 or 8172 alternator to a 1970 or newer LA style small block engine.

Note: The Powermaster 8162 alternator does not come with a pulley. AR Engineering has tooled up a billet aluminum pulley, AR210, which is the correct size and backspacing to fit the AR096, AR209 and AR209H kits. The AR210 pulley will also fit the Powermaster 8172 alternator.

Street Kits using the 60 amp Denso alternator

AR022 Big Block Denso Kit – Adapts the Toyota 4Runner alternator to any B or RB engine using the 1967 or newer water pump housing. If you have an early water pump housing then you will need to substitute the factory upper bracket for the bracket in this kit. The alternator that works with this kit is from 1985 to 1992 Toyota 4Runner and pickup trucks. Toyota part numbers that work are 27060-35060 or 27060-35061. The equivalent Bosch part number for this alternator is AL218X. These alternators are 60 amp units and come with a single grove V belt pulley.

AR020 Hemi Denso Kit – Adapts the Toyota 4Runner alternator to any 426 Hemi using the 1967 or newer water pump housing. If you have an early water pump housing then you will need to substitute the factory upper bracket for the bracket in this kit. The water pump pulley shown in the above picture is Mopar Performance part number P4510282.  The alternator that works with this kit is from 1985 to 1992 Toyota 4Runner and pickup trucks. Toyota part numbers that work are 27060-35060 or 27060-35061. The equivalent Bosch part number for this alternator is AL218X. These alternators are 60 amp units and come with a single grove V belt pulley.

AR022 Small Block Denso Kit - Adapts the Toyota 4Runner alternator to any SB engine using the 1970 or newer water pump housing. The alternator that works with this kit is from 1985 to 1992 Toyota 4Runner and pickup trucks. Toyota part numbers that work are 27060-35060 or 27060-35061. The equivalent Bosch part number for this alternator is AL218X. These alternators are 60 amp units and come with a single grove V belt pulley. If you are getting the Toyota alternator at a wrecking yard, you should go ahead and get the plug in harness at the same time. Having the correct wiring plug will make your wiring task a little easier and will make for a cleaner installation.

Installation Tips:

The Denso alternator is internally regulated, this means that the external regulator is no longer required, and it must be removed from the charging circuit. One fairly easy way to accomplish this task is to locate the 12 volt ignition switched wire that used to go the Mopar voltage regulator, and then extend it to the Denso alternator. Most Mopar vehicles used a dark blue wire for the 12 volt supply to the voltage regulator. A copy of the proper wiring diagram for your vehicle should confirm the wire that you are looking for. Double check with a volt meter before proceeding.

The Toyota alternator also needs to have a sense wire connected from the wiring harness to the alternator. This sense wire should go to a central 12 volt source that is located some distance from the alternator. The stud on the starter relay would be a good place for this or maybe even the back of the ammeter or voltmeter in the dash. What you are trying to accomplish with this remote sense wire is to tell the alternator what the voltage level in the wiring harness is so it can regulate itself. There is an excellent discussion of remote sensing at www.madelectrical.com if you are interested. Mad Enterprises also sells a variety of wiring supplies that come in very hand if you are re-wiring your charging system.

Drive Belts: We have found that a 25/64 wide V belt about 45 inches long works for most applications with stock pulleys. With aftermarket race pulleys you will probably need a belt that is slightly shorter. Gates belt #7445 fits most big block applications using stock pulley sizes. On the small block with the Toyota alternator, Gates belt #7460 is a better fit. These belt recommendations only work with factory original pulleys. Aftermarket pulleys are often smaller and will require different belt lengths.

Drive Pulleys: The big block kits work with the stock single groove pulley sets as well as the dual belt sets where the power steering is driven off the crank bolt. These alternator kits were not designed to work with the AC belt systems. For the small block, the single groove lower pulley 3614375 or the double groove lower pulley 3614378 will work. The water pump pulley on a small block should be the deep one marked 2951836. Other combinations of pulley may work but these are the ones which have been verified on our test engines.

Wiring diagram for Toyota alternator

Wiring Harness for Denso Alternators

Here is a handy item for wiring in your new alternator. A company by the name of Northwest Regulator Supply makes a Toyota repair harness. It comes with the correct plug that locks into the back of the Toyota alternator. The bare leads can then be spliced into your wiring harness using butt fit connectors.

Northwest Regulator does not sell direct to end customers, but Mancini Racing and 440Source usually keep this harness in stock. The part number for the Toyota repair kit is 50-12159. The list cost was about $6 last time we checked.