The
alternator is a Nippon-Denso unit #8172. This is the smallest OEM
automotive alternator available. It was stock on 3-cylinder cars, such
as the Diahatsu Charade and Chevy / Suzuki Sprint / Swift. No other
alternator will fit between block and framerail.
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Even
so, I had to clock the rear housing 90-degrees so that the power
terminal would face up. In stock form, it would point to the left in
this photograph, which makes it bang right into the frame. Clocking
required disassembling the *entire* alternator. A lot of work.
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This
bracket is so short that I felt comfortable using 1/4" steel to make
it. I left the upper ridges from the drill-based slotting because I
thought they looked kinda cool.
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Here
is a picture of the alternator installed. The belt is a Goodyear
#4040342, as it is 34.25" in circumferance. The pulley comes from a
Subaru Justy, which gives the 4-rib pattern that matches the Miata. Take
the nut from the Justy and it will all fit together real well.
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Here
is an image of the ECU mounted along the driver's side kick panel. I
simply drilled three holes and used really big sheet metal screws. (The
only modifications to the Datsun itself in the entire build.) This
placement allows me to use the Miata ECU harness as my entire engine
harness; the wires reach from here all the way to the MAF sensor in the
far front of the engine bay.
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The
Miata has a nice relay rack mounted on the driver's side fender. I
didn't want to see it, though, so I modified it to mount in the Datsun's
factory mono radio speaker holes high up in the passenger footwell.
First I cut the mounting tabs off of the rack itself, and drilled a
3/16" hole at each end.
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Then,
I cut and folded a simple bracket to join the rack to the pre-existing
holes in the footwell. I used 22-gauge steel because I had an odd-shaped
piece laying around. It's a little flimsy; 18- or 16-gauge might be
better. When sitting in the car, you really have to tip yourself flat
against the transmission tunnel to see this thing.
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This
little bracket, made from 1"x1" aluminum angle stock, mounts the
Miata's main fuse box to the lower mount hole for the coil bracket on
the Datsun. I threaded the two holes you see at 1/4-20 since holding a
nut under there would be a real hassle. Note the notch for a bulge in
the back of the fusebox.
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The
main fuse box looks rather nice and tidy tucked away in the corner, I
think. Never mind all the stray wires; I'll tidy them up as soon as I
know that the thing runs.
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Early
on in the swap preparation, I pulled the room fusebox from a '96 Miata.
I liked its compactness. Unfortunately, this was before I learned to cut all leads as long as possible
when pulling parts. So, when it came time to install it, I was left
with 1/2" to 2" of wire to use. It's been a year and a half, and I never
saw another '96/97 box to pull, so I'm working with it.
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To
give myself the greatest flexibility, and to do the best I could with
what little wire I had to attach to, I put female crimp spades on every
wire coming out of the fusebox. I wish I had more wire so at least these
could be proper pigtails. In the future I will probably do something
cleaner with this.
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Since
I have a '94 engine, it's OBD-I, so my diagnostic options are limited. I
have a small Radio Shack LED under the dash that used to be my "fan is
on" light & now runs to the "check engine" light lead on the ECU.
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These
two switches, to the left of the steering column, under the dash, allow
me to diagnose: one grounds the "TEN" (test engine) lead from the ECU,
which causes the check engine light to blink stored codes. The other
activates the brake switch lead to the ECU, which is used to clear
stored trouble codes. [In the end, I linked the brake switch lead to the
ECU to the brake light pressure switch (as part of the engine
harness).]
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Here
is a view of the final, wrapped engine harness before installation. I
included the oil pressure lead, the brake leads and the (gauge) coolant
temperature lead in this harness, as well as ECU-related power leads.
There is a separate harness for the general power leads, not shown.
Click on the image to see the pig tails labelled.
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How-to and handy tips for home machinists and mechanics _*_ Reviews and demonstrations of tools and equipment _*_ Project diaries of engine swaps and EV conversions _*_ Other cool stuff
Tuesday, September 6, 2011
Alternator, Harness, Fusebox -
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