need advice on high output alternator

That *sounds* like it may be a re-wrapped CS130D alternator to get that sort of power and still be under the hood on that V6 Malibu. Trouble with re-wrapped alts is that they tend to not generate high enough internal voltages to keep amp output up there when needed at idle with heavy accessory loads. They usually will not tend to hit max output until they hover around 2000 RPM at their rotor shafts.

Will it do what you need? Certainly. Will you be happy? More than likely. But let me seed your mind with doubt and see if I can light your amateur garage tech enthusiasm a little bit. :D

I'll be gentle...

For about $250, you may be able to find a rebuilt-to-new and beefed up stock GM AC-Delco alternator to fit your application that will more than meet your needs. Look into whether or not your current alt harness is compatible with a GM/AC-Delco AD244. (Adelphi Units are Decotrons too and are totally 100% swap for parts-n-all compatible)

They will hammer out a steady 100 amps for the asking AT IDLE when HOT, and do it all day long without trouble. All alternators work much less efficiently when hot, this one's just tougher and better at it's job. A junkyard pull from a GMC Yukon, a wrecked 2006 Trailblazer, or Escalade w/V-8 will snare you one that should be factory stamped for 145 Amps. The AD 244's are *underrated* and often a unit sold even stamped for 130 Amp service will still offer up 140 easily. Going the junkyard route will get you the alternator for $25 or so, and then all you will need to do is find a slightly larger serpentine belt. (By about one inch) Doing your big three upgrade with this beast in place with 2 ga. battery cables picked up new and off the shelf will more than compliment this upgrade and your audio setup as proposed.

The AD244 can be rebuilt in a garage in an afternoon with a handful of parts off E-bay to make a whalloping 170+ amps with heavier GM issue rectifiers, regulator and stator coil swap. Rebuilds with double wrapped rotor coils and further upgrades will generate upwards of 300+ amps in the same large body alternator case and still be tough as nails reliable as the original factory built Delcotron/Adelphi unit.

The real rub will be if your alternator harness will be plug-in compatible. If you had some sort of late model CS130D "crossover" make of an alternator in there with a rounded, 4-wire harness plug, the AD244 replacement will be a drop in upgrade. Given the year of vintage on your car, I would almost be sure to say that this is an 85% bet in your favor. The larger case on the alt can be happily mounted with just the two bracket holes on front. The smaller case units had a third hole to bolt them up on the rear of the case that is still present on the large case swap out - but too large to fit the original bracket. Do not worry - the two front ones will be more than solid enough to work reliably.

About the only other concern is to see of there will be other harnesses, mechanical bits and hoses that may be in the way. The bolt holes are 6.5" center to center which makes them fit about nearly all GM applications and some Dodge without a problem. But the AD244 is thicker and deeper in it's build by a fair amount and you need to double check the fit before you permanently bolt it all together.

At worse, pick one up at any automotive parts place with a bullet proof return/refund policy and check it out - then hit the junkyard to find your generator gem. :D The physically larger diameter on the case will push it out from the bracket a little more than the stock CS/AD series alternator, needing the trial and error with several belts to get it done right. Generally though, the stock belt for your year/make +1 inch will more than suffice and be safe.

I am doing this upgrade myself soon to a '95 4.3 liter Vortec Blazer once I source my AD244 from a scrap yard and pick up the GM "Heavy Duty" rebuild kit. (For solid 200 amps at idle) :D Be mindful that there were two different types of harnesses that were used on these alternators depending on the year that they were produced. Some have just two blades in a socket for the harness, plus the +BATT post on the rear. THIS ONE WILL NOT and CANNOT BE MADE TO WORK IN OUR APPLICATION. If either your car or the alt you pick up has a square plug in harness adapter with 4 conductors, one of them being fatter than the other; a simple harness conversion can be done with a pigtail replacement available over the counter at nearly all parts shops.

Good Luck!(tm)

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Life is too short to build slow computers or weak audio!

That was very interesting...Thanks for the info...Dont know if it will help but check out Ohio Generators...

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M.E.C.P & First-Class
Go slow and drink lots of water...Procrastinators' Unite...Tomorrow!

Try to get a read through this. There are links too that will help you get charts and cross-references to aid you in the search and what to say to parts dealers. I got a lot of info from here and following other searched links via Google. Typically however, if it fits in one GM, no matter the stripe, it will fit in others with minimal mods. Some folks even go so far as putting in more current capacity in Mini-Coopers, all types of Japanese makes and Chrysler Jeeps. The latter, need a lot of current to keep lights, fans and other accessories running when they are idling and crawling through rocks.

S-10 Forums : High Output Alternator Mod

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Life is too short to build slow computers or weak audio!

I find this really interesting seeing as how I was actually just looking for one for my car which is the exact same year and engine as yours. I found a 200 amp one brand new with warranty for $217 shipped. https:////MALIBU-3.1L-HIGH-OUTPUT-200-AMP-ALTERNATOR-99-00-01_W0QQitemZ390057481582QQcmdZViewItemQQimsxq20090606?IMSfp=TL090606133002r38096



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-Chris-

krazekilla224 wrote:

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I find this really interesting seeing as how I was actually just looking for one for my car which is the exact same year and engine as yours. I found a 200 amp one brand new with warranty for $217 shipped. https:////MALIBU-3.1L-HIGH-OUTPUT-200-AMP-ALTERNATOR-99-00-01_W0QQitemZ390057481582QQcmdZViewItemQQimsxq20090606?IMSfp=TL090606133002r38096

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ANOTHER non-rule-reading noob...

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It all reminds me of something that Molière once said to Guy de Maupassant at a café in Vienna: "That's nice. You should write it down."

Yup you got that right! Basically just search 2001 Malibu 200 amp alternator on google and you will find it..

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-Chris-

That would be the beast you are looking for. For a little more coin, hunt around on Ebay and other sites to pick up the $70 or so kit to build her up to 170 amp heavy duty service. Even if you do not rebuild it on your bench, keep the kit around for and if the alt weakens or fails. At worse a good rebuild shop locally can perform the swap out of parts and rebuild it for you on the cheap. Luckily, rebuilding these devices are pretty easy to do with a reasonably well appointed toolbox in an afternoon and you get to learn something along the way. :D

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Life is too short to build slow computers or weak audio!

Wolfox, I think i have hit a snag in my plans.  After closely looking at the casings on these I've noticed that my factory alternator has one mounting hole that faces the pulley on the front and the other two face down toward the ground.  The ad 244 looks like it has two bolt holes on the front.  Are you aware of a workaround for this or any versions of the ad 244 with this style mounting?

Ooooooh, no - this is a new one on me. Usually they are just this bracket hanging off the front of the block that also supports power steering pumps, A/C, whathaveyouwhatnot. They typically bolt straight through, parallel to the body of the alternator. Get your cellphone/digital camera out for me and *please* post me photos from a few angles?

On my Blazer, there is a third "leg" that bolts to a support bracket against the back of the small body CS130D. Omitting this part after torquing the nut off of the exhaust head that keeps it in place is the only "mod" I would need to do. (I would just use the two front bolt holes to support the whole works)

I got to see what you are looking at there - but it is nothing to fabricate a bracket, and relatively inexpensive to have done for you in light of the "Big Picture(tm)" of your megawatt install.

AD244's only come in one style...

Stonkin' *HUGE*. :D

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Life is too short to build slow computers or weak audio!

Here is something interesting-
A Google search provided a clue, now to clue you in on the breadcrumb trail:

What WILL fit your application perfectly is a CS144, dual rectifier, heavy duty re-manufactured unit with a *BRACKET ADAPTER*. Yes kids, you can sleep well tonight - I found the solution. A little pricey - but a single rectifier, standard duty reman will set you back $209. (140 amp)

Going as high as 250 amps will strain the bank account for about $470.

Either way you decide, they also sell a bracket U-clip adapter to fit '01 3.1 liter V-6 for $30.

For fear of angering the admin and forum gods (The only thunder I like booms overhead, or in my truck - not in my computer!) dare I just hand out a link to the reman's product page? Or better yet, Google search for "2001 chevy malibu 3.1 liter alternator upgrade" and it's the first page that pops up. Short description of Googled text:

"Get more power, upgrade your CS130D to a large case CS144 or the Extreme ... for your 1996-2001 GM vehicle with the 3100, 3.1 liter or 1999-2001 3.8 ... The installation shown below is on the 1999 Chevy Malibu with the 3100cc\ 3.1 V-6 engine. If you have this alternator on your GM 3.1 engine you can install up to ..."

I will go and hide for a little while and see if my newly minted account and login here gets smitten. :D

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Life is too short to build slow computers or weak audio!

Do you know anything about how the CS144 compares to the AD 244?  Do you know if it has the same center to center for the mounting holes? I am thinking that the same thing could be done with the AD 244 and I have found a good used AD 244 145amp for under $50.  The bracket they show just looks like a piece of C channel they drilled some holes into to me.   

The CS144 is a bit smaller in diameter on the case dimensions in all directions. Looking at the photos on some sites that show the upgrade/mod would indicate mounting problems with anything larger than the CS series unit. If you will note, it looks like heater hoses run right up against the back of the CS after it is installed. Also, the case is cast with slightly different lugs to pass the bolts through, maybe because of the tighter space it was made to go into. The AD244 would be grossly oversized if you managed to adapt it - looks like it would literally bulge your hood out when you closed it. I *USED* to have a vehicle with a 3.1 60 degree GM V-6 to look at, but it was hauled away to the scrappers a month ago due to a seized block. Otherwise I would go outside and figure it all out based on what I know of the AD244's at the moment. Let me get on the trail of looking up the sizing and mounting hole spacing and get back to you on that. That is something I just do not know off the top of my head.

I just find it intriguing at the moment that nearly all 3.1 liter V-6 GM blocks recommend the CS144 as the only upgrade path if you need more than 105 amps stock on the CS130D. Also of note, on CS series alts, the number indicates the outside diameter of the stator coils - since the form that holds them in place is externally visible (The GREEN/ black band in the center of the alt) you can do a fast and dirty size up visually if the differing units were side by side in front of you.

Okay, let me get on the trail of finding overall dimensions and spacings...BRB.

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Life is too short to build slow computers or weak audio!

Okay, the bolt spacing on the front is the same as the AD244 - 6.5" center to center on a GENERIC case. (More below) It is also 6.5 inches from the rear +Batt post to the front of the external fan. It is just a tad larger in diameter (14mm) over the CS130D. The AD244 is enormous compared to the CS144, and I honestly do not think it would easily allow you to close the hood, let alone fit on top of the block with all that plumbing. I sure wish I had the stuff in front of me to say with 110% clarity and truth and make measurements.

Now I have held an AD244 in my hands once, 15 pounds compared to the CS's svelte 10 pounds and much deeper. It looks like a CS130 all mutated. A CS144 is merely a tad bulkier than the CS130D, making it a direct bolt in truck job easier than a car mod. 3rd gen. J-body enthusiasts use this alternator in place of their 130D's with minimal bracket/alternator casing mods (grinding brackets down or the casings of the alt to make it fit mechanically - only a 1/16" needed in each case it would seem). The AD244's depth and overall mass does not play nice in tighter car bodies and builds but the CS144 can be made to perform just like the large case AD244.

If you like to thump and bump with a kilowatt in the trunk, find at least a heavy duty 140 amp CS144 with a casing cast to the bolt pattern you need - that is the enigma here...

NO online resource I could find will directly state what style of CS144 they have in stock. They made them with a myriad of diffe4rent bolt lug spacings and orientations to fit into many, many passenger cars and light trucks as a factory Hi-Output option. GM vehicles in Police and emergency applications carried this alternator as stock in a 140amp package.

Special applications can be built into casings to match your specific block spacing and orientation in double rectifier hop-ups upwards of 300 Amps continuous service, but again - you got to hunt, call and request it after supplying vehicle specific data. Otherwise, a generic cased CS144 next to a 130D in every comparison photo I see on the web looks like a slightly bigger twin. The AD244 in comparison to either small case alts is a Goliath.

List of *confirmed* donor vehicles to try in the boneyard for a CS144 @ 140amp unit would be:

* Corvette (94-96 5.7L exc.ZR1 - 84-85 all - 80-82 HD opt. only)
* '93~95 Cadillac DeVille
* This alternator also fits directly into these vehicles, no mods needed: Suburban - Blazer - Tahoe - Jimmy - Yukon - Safari - Sierra
C, K, R, S, T, V Series trucks - Astro & G Series van 1986~2006 (These are DIRECT bolt in applications w/*gerneric* cases on these trucks - harness adapter may be required depending on the type you pull from the junker and if it was an aftermarket mod/upgrade)
* 140 Amp version can be found in 1994~96 Impala SS/Caprice (Factory H.O. package...

In short - hunt the yards in addition to the web, these things were put in a very wide reaching installation base and as a factory kit upgrade at time of vehicle order. Snap a photo of your alt, find a donor and if a bracket was used to get it into a car, snag that too to make up for clearance issues that would otherwise have that alt smacking into a valve cover or something.

Man, I thought that this was going to be easy, but I got your back buddy!

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Life is too short to build slow computers or weak audio!

I really appreciate all the help and info you have given me.  I found a cs 144 on ebay from a deville.  It says its a 140 amp for around 50 bucks.  Do you know if it has the amp rating on the casing somewhere?  I was looking at the knukonceptz website alternator guide and it says that 98-99 luminas had a 140 amp option.  Also do i need to change the plug to make these work?

I did some field research the past two days. The CS-140's wound for 140 amp service (high output) that could find st the wreckers had ovsl, 4-pin plug. Electrically, they would be a drop in replacement for my CS130D already on my Blazer. I found no external markings that would indicate the capacity of them. Since they were so old, the Remy/Delco sticker on them was long gone, so I could not reference a part number for you. Now - I got to look at the AD244 and a DR44G - both are mechanical/electrical twins. They too had an oval 4-pin harness and would be a mechanical fit fo my truck with a 1" oversized belt. Though the casings on the large body alternators were bulkier, their overall length was similar to an CS130D with identical mounting lug locations. (Again, speaking for myself and my truck) So I would say at this point, locate a junker source that has the components you are desiring and size them up side by side to make sure that they fit in your car's application. A truck affords the luxury of generic locations and sizing with room to work with.

Nobody could give me specific details of upgrading a 3.1 Malibu but from what I can tell from anything I found online, a bracket of some sort will need to be made/modified to make up clearances to keep *any* upgrade other than a rewound CS130D from bumping into the block. One CS140 the fellow could show me that was wound for "Heavy Duty" 140 amp service came off a low mile, wrecked Caprice Police packaged squad car, '05 model year. (Looked like an aftermarket rather thana factory mod) There was a bracket adapter that was on the block to accommodate the bulkier case.

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Life is too short to build slow computers or weak audio!

I had to look around for an answer to your plug question, I guess either I was imagining things in the sweltering heat down here or just plumb forgot - Vehicles that have a CS130D alternator as stock from factory will need a wire harness adapter to fit an OEM style CS144 of any build or type. The harness adapter is part # D1-W1206. Vehicles with a CS130 alternator (Without the D, if you please note) will NOT require an adapter of any kind.

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Life is too short to build slow computers or weak audio!

I scored a 140 amp CS144 at the junkyard for $45!  I may have stumbled on an easier solution to the mounting issue.  The older gm 60 degree v6's had cs144 style alternators on them from the factory.  I think that a bracket for an older engine will bolt up to the new 3100.  The only hang up is that the belt is routed differently on the older engines than on mine.  I don't have an older engine to look at so I'm not sure if it would be a simple matter of changing the belt routing and installing the older bracket or if it would be more involved.  Does anyone have an older gm 3.1 or 2.8 they could take some pictures of?