My Official OM617 Toyota Pickup Repower Thread

[OM617YOTA]

Well, woke up around 7:30am Saturday. Everything went as planned until about 8:00am Saturday, then various other urgent priorities came up. I was able to get them all squared away, but the only progress I got done on the truck was the vacuum reservoir.

My vacuum pump "bounces" a lot, pumps vacuum pressure down and then shuts off, then real fast on off on off on off for a little. I thought this was due to a little bit of air leaking back in as the check valve closed, and that a larger vacuum system would help. Added the vacuum reservoir, no change at all. Changing out the relay helped a bit. It DIDN'T do this when I first installed the system. Thinking the vacuum switch may have failed.

Right now, getting the big alternator installed is top priority. Truck has failed to start for me a couple of times, and each time a jump start got it going just fine.

Pic 1. Vacuum reservoir moved out of it's normal resting spot to show the attachment and plumbing.

Pic 2. Vacuum reservoir in it's resting spot. Not held down by anything but the mass of hoses, wires, and cables in the area right now. Yes, that water bottle is my coolant catch can. I have plenty more pipe and some fittings, I may built a more permanent catch can out of those materials when the priorities come around.

[OM617YOTA]

Started w/ the Delco 22SI conversion and hit a snag. What's the easiest way to pull the alternator bracket off the block without pulling the turbo oil drain?

[OM617YOTA]

Got a start on the alternator swap. Bracketry from old alternator removed, started fabbing up bracketry and such for the new Delco monster. Going to re-use the old aluminum mounting bracket, and maintain all the original parts in re-installable condition. If I need to I can go back to the old system at any time.

1. New and old alternator compared
2. Side of the block where the alternator bracket mounted. The stud that's been removed was to get the bracket off past the turbo drain tube.
3. Stock alternator bracket held up to new alternator w/ bolt through the other side so it pivots. I'll use a turn buckle for belt adjustment. Obviously a direct shot from the bracket to the alternator ear won't work, so I'll build a spacer.
4. Delco pulley next to stock alternator pulley. Delco pulley is double V belt, with different spacing than the stock MBZ double belt pulleys. Plan is to take the stock MBZ pulley(from previous defunct alternator, leaving functional stock MBZ alternator untouched and functional) to a friend's machine shop to bore it out to the right diameter for the Delco alternator.
5. Beginning of spacer so that turn buckle will clear cooling fan and alternator body.

[OM617YOTA]

1. Cardboard mockup of spacer before I cut it out of 1/4" steel plate.
2. Spacer during fabrication. It'll bolt to the alternator mounting ear, and part of the spacer will come down to rest on the alternator body. Will probably weld a tab to spread the force on the alternator body out more.

[Cadin]

Nice. That Delco 22si, is a monster!

[OM617YOTA]

Just a quick update. Anyone getting sick of reading these yet?

Got a bit more work done on the bracket fabbing, and a friend is going to bore out the donor pulley off the old defunct alternator to match my 22SI.

Pics are just a couple views of the bracket connection to the pivot point of the alternator. Still need to build an adjustment system, planning to use a turn buckle for that if I can find one that's both beefy enough and short enough. Also might modify the stock adjuster, though I think if I do that it'll interfere with the heater hose connection. We shall see.

Thanks Cadin! I should have nooooooooo worries about power after this. I'm sorry I had to bow out of meeting up, some family issues came up and had to be dealt with. Next time you head down this way, let me know.

[Stretch]

Well I'm still reading!

I must say I don't like the look of your spacers on that shaft - in my experience all of those washers will move and you'll end up with stuff coming loose. (<= Poor attempt at constructive criticism?)

[ROLLGUY]

Originally Posted by Stretch

Well I'm still reading!

I must say I don't like the look of your spacers on that shaft - in my experience all of those washers will move and you'll end up with stuff coming loose. (<= Poor attempt at constructive criticism?)

Agreed. Why not use the spacer from the old 240 alternator?

[OM617YOTA]

Thanks folks. This is part of why I post, so you guys can point out dodgy bits of my plan.

I skipped using the stock spacer because it would have to be cut down. I wanted to leave all the original stuff alone and functional so that I have a backup plan if needed.

I'all do some more planning!

[Stretch]

Or put up a new thread => WTB alternator fixing hardware...

[OM617YOTA]

I'm using nuts on allthread to act as adjustable "spacers", with washers and lock washers. I only used the stack of washers where there wasn't room for nuts for adjustability. I may be wrong, but I think I'm going to give it a shot and see what happens. I should be able to get everything set up so it'll pivot freely, get the belt tension adjusted, then lock everything down with the nuts on the allthread.

We'll see, and you're all welcome to say I TOLD YOU SO on down the road.

[ROLLGUY]

Originally Posted by OM617YOTA

I'm using nuts on allthread to act as adjustable "spacers", with washers and lock washers. I only used the stack of washers where there wasn't room for nuts for adjustability. I may be wrong, but I think I'm going to give it a shot and see what happens. I should be able to get everything set up so it'll pivot freely, get the belt tension adjusted, then lock everything down with the nuts on the allthread.

We'll see, and you're all welcome to say I TOLD YOU SO on down the road.

Nothing wrong using this setup for testing and getting the allignment correct. When all is right, PM me with the length spacer you need, and I will cut one and send it to you.....Rich

[Stretch]

^^^^He's a good lad.

[OM617YOTA]

Rich-

Thank you sir! I may take you up on that. Incredibly generous!

Friday was my birthday, today is my girlfriend's birthday, we make one party of it and needless to say I got nothing practical at all done this weekend.

[ROLLGUY]

I have plenty of DOM tubing that I use for my A/C plates in 3/8" & 1/2" ID. Just let me know the length, it is no problem....Rich