CS144 ALTERNATOR

The Delco CS144 alt is a popular swap in many automotive venues. 1st gen V6 folks have been doing the swap for 20 plus years. They were used in many vehicles and are fairly common/cheap at parts houses. A "Denso to Delco" adapter pig tail is available so the only wiring modification is the power cable.
While 140 amps is at the low end of what I consider "high output" the real attractive feature is the low RPM output of around 100A at idle. If one really needs more there are "bolt in" kits that pump it up to 200A max. It can also be converted to "one wire" hook up with a self exciting regulator.

I jumped into the swap with the predetermined mindset that it "fit" when mounted with a 1/4" spacer to keep it towards the front ear of the mount bracket. After all, folks had been doing it for years.

When I first hung it in place, as far forward in the OE bracket as possible, the pulley sure seemed to line up. Even with a casual straight edge against pulley face the belt looked parallel, so I cut a spacer to completely fill the gap at the rear. With a "snug" fit it ended up closer to 3/8".

Fast forward a couple years and this thread came up.
https://www.tacomaworld.com/threads/cs144-alternator-questions.696737/#post-24643921

Specifically this post where @mechanicjon determined he needed a pulley with a larger offset.
https://www.tacomaworld.com/threads/cs144-alternator-questions.696737/#post-24674509
The thread as a whole has a bunch of the incidental fitment details.

Since I "thought" my install (and 2 others) lined up (exact same alt mechanicjon used) I figured there must be some variance in the Toyota mount bracket over the years along with my slightly thicker spacer.

Fast forward a couple more years.
I had noticed that it took more belt tension than I thought appropriate to keep the belt from slipping at start up (short belt chirp). Then one day I noticed slight fraying of the belt cords on the front edge. So with mechanicjons pulley swap in mind I broke out the straight edge again. Casual glance and it still looked good. Then I checked it again with the eyeballs good and lined up perfectly over the belt. It took some effort to get in this position while holding the straight edge at the same time. What do you know, belt and straight edge not parallel. Not off by much but off non the less.

This misalignment likely has gone unnoticed by most and frankly close enough for most. Once aware of something like this I can't let it go.

Mechanicjons shot showing the need for a different pulley offset. I added the yellow lines showing the important difference between the two alts.


Invoke some sanity and just get the right pulley, not what I did.
My solution since I had the means was to cut a relief at the front of the alt case. Used a 2 wing flat top blade from an 8" dado set on a 10" table saw. Screwed together a quick "sled" from scrap wood to ride against the saw fence and cradle the alt. A couple of passes later and bingo. As a result it needed almost a full 1/2" spacer. Also see the "fuzz" on the front edge of the belt and how far the bushing protrudes under the pivot bolt head.




Now all is well and life can go on.

 

So, now that you now know all of that, in a nutshell, what would one have to do, to after buying a CS144 alternator to get it to fit properly?

 

I would get the correct pulley that sticks forward a bit. I would also use a power steering pump belt (longer) in place of the stock length alt belt to avoid trimming the oil cooler hose.
I think I mentioned this in one of the threads but I would get a reman DELCO from a local source as opposed to the "new" Delco #335-1048 that MJ and I used. The "new" Delco is actually made in Mexico "for and sold by Delco" as a service replacement. Picture of the box here https://www.tacomaworld.com/threads/cs144-alternator-questions.696737/#post-24650938
My 335-1048 came from Amazon and it took 3 to get one that was not damaged in shipping (bent shaft both times). They happily and promptly sent replacements but a pain never the less. The other swaps I did all arrived fine.
A Delco made unit will have the Delco logo cast on the rear.

That being said my #335-1048 has been performing well. It's one of those things that will come down to ones own level of OCD.

The link that @mechanicjon posted for the pulley is dead, he might chime in.
I am certain the pulley can be found here but I don't have the specs for the one he used other than it's a 17mm bore.
https://store.alternatorparts.com/17mm.aspx
Once located, the "application" model/make/year etc. could be used at other parts houses.

 

https://store.alternatorparts.com/p...ulley-for-delco-cs144-series-alternators.aspx