ALTERNATOR UPGRADE! Suzuki F6A Kei Van Mini Truck - Bass Van Build #07

After starting this project a while ago, I finally had the time to complete the alternator upgrade on my Suzuki Every DE51V kei van, swapping out the stock 40A alternator for a much more powerful 115A unit. The original 40A alternator was fine for basic functions, but over time, as I added more accessories—like a better audio system, extra lighting, and other electronics — it became clear that the stock alternator wasn’t up to the task. It struggled to keep up with the increased electrical demand, and I noticed occasional voltage drops and dimming lights, which isn’t great for the health of the battery or the vehicle’s overall performance.

By upgrading to a 115A alternator, I’ve ensured that my van can handle these heavier electrical loads with ease. Now, everything runs more smoothly and reliably, and I don’t have to worry about stressing the electrical system. The extra capacity helps maintain battery health and gives me peace of mind knowing that my van’s electrical components, both old and new, are well-supported. It’s a relief to finally get this upgrade done, and I’m excited to see how much better the van performs with the improved setup.

I purchased a brand new alternator that is designed and built for Mitsubishi 4D56/4D55 engines like the Pajero, Delica, L300, Strada, and the Triton.

Then I proceeded to weld an alternator conversion bracket made of thick 8mm steel flat bars. Welding is fun I tell you!

I did some minor modifications on the new alternator by cutting the axle that drives the vacuum pump and some of its protruding aluminum mountings, just to make sure it'll perfectly fit within the small engine bay of the rear engine Suzuki Kei van.

I also did cut up the stock AC compressor and removed all its inside components and converted the whole thing as the belt pulley or some sort of fixed belt tensioner.

I purchased a bit longer 4PK serpentine belt because the old one won't fit no more.

Put everything back, fired the engine on and voila! The new alternator is now up online and the serpentine belt is perfectly aligned! No belt squealing, no belt slipping and no built dust just a little hehe.

Wired in some 3000w RMS mono amplifier and a 1200w RMS subwoofer for some bass-heavy demo! Overall voltage is now stable at 14.5v idle, playing bass heavy music.

Turning on the high beam lights, wipers, radiator fan, hazard lights will put the voltage at about 12.7v when the van is running. Before it will dip down to 11.2v! Big improvements I tell you for sure!

GREAT SUCCESS!

00:00-00:55 CUTE PUPPIES INTRO
00:56-02:13 REMOVE STOCK ALTERNATOR & BRACKET
02:14-02:36 BRAND NEW 4D56 ALTERNATOR
02:37-03:08 DIY ALTERNATOR ALIGNING JIG
03:09-05:33 MOUNTING BRACKET FABRICATION
05:34-05:54 NEW ALTERNATOR MINOR MODIFICATIONS
05:55-06:20 MOUNTING BRACKET TEST FIT
06:21-06:28 INSTALL LOWER BRACKET
06:29-06:50 CONVERT AC COMPRESSOR INTO BELT PULLEY
06:51-07:42 MOUNT THE NEW ALTERNATOR
07:43-07:59 RUN ENGINE AND TEST
08:00-9:05 MODIFIED BELT COVER IN PLACE
09:06-09:25 ALTERNATOR UPGRADE SUCESSFUL
09:26-10:44 BASS HEAVY DEMO