I have a 1600 16v swapped into a Samurai. The stock 1600 alternator is 50a which seemed to just about be able to run the stock electrics but I have fitted electric seats and will probably be looking at additional lighting and a compressor for a locker at some point so needed something more than the stock alternator. When I had the heaters running, the electric seats on, and full beam lit up, the battery would drain quicker than it would charge with the stock unit.
Long story short, I bought or borrowed many different alternators until I could find one that would be a decent step up but that could also be fitted easily. In the end I found a Nissan unit which was a near enough direct fitment but with an 80amp output - 30amps more than the original one.
As I said, I have a 1600 16v, I have no idea if this will fit any other Suzuki engines but next time I look at someones truck I'll make a guess at what other engines it will likely fit.
The plugs on the Suzuki alternator and the Nissan alternator are different in design. I didn't want to cut my loom so I could always throw the stock item back on in an emergency. I bought two plugs and made a little adapter harness. The only other thing you need is a 12mm spacer to space out the bracket on the block to the arm on the altenator. I mahcined one on my lathe but you can just use a stack of washers if you don't have access to a lathe.
Anyway, here are all the parts you need in order to do the 80amp alternator upgrade yourself:
You need this alternator.
You need this plug, and this plug. Cut them together to make a small adaptor harness.
You need a spacer like this or a small stack of washers. My spacer is roughly 20mm in diameter, 12mm thick, and has an 8mm hole through the middle.
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That's it. Easy 80amp upgrade.
Caveat: This Nissan alternator is from a CA18DET engine as fitted to things like a 200SX/Silvia etc. The DET suffix on Nissan engines denotes a turbocharged version. There are several other CA18 variants that are not turbocharged. The alternators from these CA engines are completely different and will not fit.
I also suspect that there will be other Nissan engines that may well have suitable donor alternators which will both be higher amperage and fit. I have quite a bit of Nissan stuff so will update this post if I work out other alternators that fit because these ones from the CA18DETs are getting a little rarer.
Here's the finished thing. Works perfectly and has plenty of amperage so far. You can see the small plug adaptor harness in place too.
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