1. Gather Necessary Parts and Tools:
* Alternator: Make sure you purchase an alternator designed for your specific application. The correct amperage and mounting style are crucial. You might need an adapter bracket if you're not using a direct replacement.
* Adapter bracket (likely): Slant-six Dusters originally used generators. You'll almost certainly need an adapter bracket to mount the alternator to the engine. These are readily available from automotive parts stores or online retailers, but specifying the correct one for your year and engine is essential.
* Pulley: Ensure the alternator pulley is compatible with your existing serpentine belt system (if you have one) or the drive system you plan to use.
* Wiring harness: You may need a new wiring harness or a conversion kit to adapt the alternator's wiring to the car's existing electrical system. This is often the most complex part of the conversion.
* Belt: The correct size serpentine belt or V-belt.
* Bolts, nuts, and washers: Use the correct size and grade hardware.
* Wrench set, sockets, screwdrivers, pliers, wire strippers, crimpers (if applicable).
* Repair manual: Absolutely crucial for specific torque specs and wiring diagrams.
2. Preparation:
* Disconnect the battery's negative terminal: This is a critical safety precaution.
* Remove the old generator (if applicable): Loosen the mounting bolts, disconnect the wiring, and remove the drive belt.
3. Installation:
* Install the alternator bracket: Mount the adapter bracket to the engine block using the provided hardware and your repair manual as a guide. Make sure it's securely fastened.
* Mount the alternator: Attach the alternator to the bracket.
* Connect the wiring: This is the most challenging aspect. The repair manual will have a wiring diagram. You'll need to connect the alternator's:
* B+ (battery positive): Connects directly to the battery's positive terminal (or a fused connection point).
* Battery or Ignition wire: Often a switched 12V supply to engage the alternator.
* Ground wire: Connects to a good ground point on the engine block.
* Indicator/Warning light wire: Connects to the alternator warning light on the instrument panel. This wire is crucial for the charging system warning light to work correctly.
* Route and secure all wiring: Keep wiring away from moving parts.
* Install the pulley and belt: Align the alternator pulley with the crankshaft pulley and install the correct belt. Check for proper belt tension. A tensioner pulley might be necessary.
4. Testing:
* Reconnect the battery's negative terminal.
* Start the engine: Check the alternator output voltage with a multimeter. It should be around 13.5-14.5 volts at idle.
* Check the charging system indicator light: It should go off once the engine is running.
Important Considerations:
* Grounding: A poor ground connection can prevent the alternator from working correctly. Ensure all ground connections are clean and tight.
* Wiring: Incorrect wiring can damage the alternator or other electrical components. Follow the wiring diagram in your repair manual precisely.
* Belt Tension: Improper belt tension can cause premature belt wear or alternator failure. Refer to your repair manual for the correct tension.
* Amperage: Choose an alternator with sufficient amperage for your vehicle's electrical needs.
Disclaimer: This is a general guide. Improper installation can lead to damage to your vehicle or personal injury. If you are not comfortable performing this task, seek the help of a qualified mechanic. The use of a factory service manual is strongly recommended.
