|
|
 |
Simon Motorsports
Mercury V6 Alternator System
Evaulation and Installation
Article and Photos by Greg Terzian
1 2
3
System
Installation
The system
includes everything you’ll need for the complete installation onto any 2.0,
2.4, and 2.5-liter Mercury engine. It must be noted however, that when
installed, the alternator system does add several inches of width to the
engine, therefore, only an “Alien” style Mercury cowling (factory or
aftermarket) can be used once this system is installed. Due to the
alternator's high output, the engine must be equipped with a voltage
regulator to avoid an overcharging condition. Fuel injected engines
already have this component, but many carbureted models do not, so it must
be added.
The complete kit
consists of both alternator brackets, the alternator itself, the drive
pulley, extended flywheel pulley bolts, extended head bolts, a drive belt, a
pre-cut and crimped positive lead to the engine starter solenoid, spacer
washers, and thread-locking compound.
The total
installation time (not including cowl swap) should take no longer than 15 minutes, using common hand tools. The tools required for the job
are a torque wrench, flywheel holding tool, and various SAE nut sockets and
hex drivers.
- The first step
is to disconnect the negative terminal from the battery. If you own a
fuel-injected engine, disconnect the ECM harness, since you will be rotating
the flywheel during installation. If you own a carbureted engine, remove
the spark plug wires to prevent accidentally starting the engine.
- Using a
suitable flywheel holding tool, secure the flywheel while using a socket
wrench to break loose the eight flywheel hub bolts. Remove the flywheel hub
bolts and carefully remove the spreader ring plate underneath. This
procedure applies to all flywheel types. For this installation, we used a
JSRE Drag flywheel.
 |
 |
 |
Left:
Holding the flywheel with the appropriate tool
while torquing the hub bolts.
Middle: Removing upper starter bracket.
Right: Installing alternator starter
bracket. |
- It is important
that all mating surfaces on the flywheel, pulley, and spreader ring plate
are completely free of dirt or paint. These contaminants will affect the
alignment of the flywheel pulley. After insuring that all surfaces are
clean, carefully place the flywheel on top of the hub, then place the
flywheel pulley on top of the flywheel (see picture to note position of the
pulley). Place the spreader ring plate over the pulley and align the
flywheel parts. Locate the eight 5/16-inch grade-8 extended flywheel pulley
bolts from the Simon Motorsports alternator system. Apply a modest amount of
thread locking compound to the last five threads of the bolt and thread it
in – finger tight only. Repeat this step for the remaining seven
flywheel bolts, and snug the bolts with a socket wrench, being careful not
to cut your hands on the flywheel starter teeth. It might be wise to wear
work gloves for protection while handling the flywheel.
- Secure the
flywheel with a flywheel holding tool, and begin torqueing the flywheel hub
bolts to 30 ft. lb. Be sure to torque the bolts in a cross pattern, four
bolts at a time. For example: 9, 3, 12, and 6 o’clock, then repeat on the
remaining four.
- Next, remove
the upper starter mounting bracket and set it aside. Locate the Simon
Motorsports upper starter alternator bracket and position it with the
alternator mount facing upward (see picture). This replaces the Mercury
upper starter bracket. Don’t forget to replace the negative battery
terminal if so equipped at this location. Apply a small amount of thread
locking compound to the threads of the two 5/16-inch hex key bolts and
torque them to 20 ft. lb.
 |
 |
Left:
Installing cylinder head bracket.
Right: Cylinder head bracket installed. |
- Remove the two
upper right bolts from the starboard cylinder head and set them aside.
Position the rear alternator bracket over the cylinder head as shown. Slide
one 3/8-inch washer over each of the two Simon Motorsports grade-8 3/8-inch
cylinder head bolts, and secure the rear alternator bracket with these.
Torque to 40 ft. lb. Note: The kit includes four 3/8-inch spacer washers
that are positioned on the inside of the cylinder head bracket, if needed.
These may be useful for installations that require more belt tension due to
milled heads. Install the bracket without the washers, and if more belt
tension is needed, add as necessary.
 |
 |
Left:
Starter and cylinder brackets installed,
ready for alternator.
Right: Mounting alternator assembly to the
installed brackets. |
- Locate the red
positive alternator wire and secure it to the alternator’s mounting stud.
Locate both Simon Motorsports 3/8-inch hex head alternator mounting bolts
and stainless washers. Secure the alternator to the brackets as shown,
using a small amount of thread locking compound on the bolts. Torque to 20
ft. lb. Be sure that the alternator is not pinching any wires in the
vicinity.
 |
 |
Left:
Torquing alternator assembly bolts.
Right: Complete assembly installed, ready
for drive belt. |
- Locate the
alternator drive belt, and place one side around the alternator pulley.
Place the other side of the belt halfway around the cylinder head side of
the flywheel pulley (see picture). While holding the belt in position
against the flywheel pulley, use a socket wrench to rotate the flywheel
clockwise, and slowly load the belt on the pulley. Be careful not to pinch
your fingers on the belt as it engages the pulleys. Continue rotating the
flywheel until the belt is completely loaded onto the flywheel pulley.
Check the belt tension - there should be no more than ½-inch of deflection
in the belt. If more belt tension is required, remove the alternator and
the rear bracket, and add one set of spacer washers.
 |
 |
Left:
Holding belt in place while loading it onto
the pulleys.
Right: Rotating the flywheel with a socket
wrench to install the belt. |
- Connect the
alternator positive terminal to the positive stud on the starter solenoid.
Check to make sure no wires are near the flywheel teeth, and that all
electrical connections are secure. Reconnect your ECM or spark plug wires
and your battery. After five hours of operation, check your belt tension
and re-torque your cylinder head bolts.
 |
 |
Left:
Installing alternator positive feed wire.
Right: Complete installation. |
Next Page: Performance and Impressions
|
 |
|
 |
