I've decided to fit a second alternator and battery on my truck, for the winch(s).

I thought I would detail this mod here, so that it may help other members who wish to do the same. I'm doing this on my vitara, but it could be done very similarly to other trucks.

• Firstly I cut a piece of 70mm x 10mm flat steel at 85mm.
  
• I then offered it into place on top of the bracket which holds the power steering pump, and marked where the 2 threaded holes in the power steering pump bracket are.
  
• I then drilled the 2 holes and bolted it in place.

• Next I cut 2 x pieces of steel 25mm x 35mm x 10mm. I drilled a hole through the middle of both these pieces of steel.
  
• I then welded a nut onto one side of each piece to create captive nuts.
  
• I then bolted these 2 pieces of steel to the alternator and positioned the alternator in place on top of the plate I'd bolted on top of the power steering pump.
  
• I then adjusted the position of the alternator so that it was perfectly in line with the other 2 pulleys. Once i was happy with it I tack welded it in place before removing the alternator and fully welding all the way around.

• I then cut a piece of 40mm angle at 90mm long. I then offered it up against the 2 threaded holes on the engine block, to the left of the exhaust manifold, and marked these 2 holes.
  
• I then drilled the 2 holes and another one on the other face of the angle.
  
• I then bolted this in place and made sure everything lines up. I also checked that the alternator belt tensioner/adjuster slides ok, which it does.

• I've removed the brackets for painting. Once they're dry, i will refit them with the alternator. I will then remove the power steering belt and use a piece of string to measure the length I need the new belt to be.

The alternator I'm using is a 70 amp vitara one and the battery I will be using is a heavy duty high amp diesel one.

If you feel something has been missed or you have something to add please feel free to PM the author.

Please remember that members who write How-To Posts do so voluntarily and have spent time on doing this for the benefit of all members so be nice.

so ive now got my second alternator bolted in place.

so next i removed the poly V belt that goes around the main pulley on the front of the engine, and around the power steering pump.
next i used a piece of string and looped it around the main pulley, power steering pump pulley, and the new second alternator pulley, and pulled the ends of the string together, so that the string was taught, this is the length i needed my belt to be.

when measuring like this, ensure the tensioner for the power steering pump belt, and the new second alternator, are at there slackest.

this is so that when you fit your new belt you have enough adjustment in the tensioner to tension the belt.

i then took this piece of string to my local motor factors and purchased a poly V belt, the correct length.

i fitted my second battery under the bonnet, behind my passenger side headlight. some people choose to fit theres in the boot, or behind the front seats.

1 thing that should be considered, is that idealy if you have your second battery inside the vehicle, it should be in a suitable battery box, like a marine battery box. so that in the event of an accident, there wont be battery acid leaking all over the occupants.




*will update showing how i wired the alternator up, very soon*