Accessory Instructions

Revised September 2010

Alternator Assembly - Avenger - 850-54

Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Qty.
1
1
1
1
1
1
1
1
3
4
1
7
1
1
2
1
1

Part #
850-41
850-181
850-59
850-45
850-58
850-180
850-54HDW
117-94
108-03
112-167
118-52
108-05
108-24
108-27
112-20
118-04
112-22

Description
Alternator - 40 amp
Bracket Assy, Altr Engine Lower
Pulley, V-Belt
V-Belt, 3/8" x 19"
Wire Harness
Bracket Assy, Altr Engine Upper
Hardware Kit comprised of:
Pushnut, 5/32" Shaft
Lockwasher 1/4" Split Ring Zn
HHCS M8 x 1,25 x 80 mm Zn
Fuse, 10A 2-Prong
Lockwasher 5/16" Split Ring Zn
Flat Washer .34 x .70 x .06 Zn
Lockwasher 7/16" Split Ring Zn
HHCS M8 x 1.25 x 25mm
Connector, t-Tap 14-18 Awg
HHCS M10 x 1,50 x 50mm Zn

Ref. Qty. Part #

18
1
112-63

19
1
850-52
20
1
112-65
21
1
117-62
22
1
117-63
23
1
613-45
24
2
112-97

Description
HHCS M8 x 1.25 x 35mm
Gr 5 Zn
Block, Adjuster
RHMS 1/4 - 20 x 3" Phil Zn
Nut, Hex M10 x 1.50 Zn
Nut, Hex M6 x 1.0 Zn
Insulator, Terminal (6ga.)
HHCS M6 x 1,0 x 25mm Zn

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Tools Required
Combination - Wrench 12mm ,13mm, 16mm, 7/16" &
Socket - 10mm, 12mm, 13mm, 16mm, 17mm, 18mm deep
Slot screw driver

Ratchet
Pry bar 6" - 8"
Electrical tape

OPTIONAL: trouble light

Detailed information on standard workshop and safety procedures, and general

installation practices is not included in these instructions, which have been prepared
to assist qualified and competent personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any
procedure performed, including those procedures outlined in these instructions.
Before performing an installation operation, an individual must have determined
to his/her satisfaction that personal injury or vehicle damage will not result from
the installation procedure, working environment or tools selected.

Vehicles Affected: Avenger Models

Instructions:
1.

Separate the contents of the hardware package into size groups. Check all the items against the List of Parts.

2.

Remove the hood and firewall. NOTE: Removing the engine will ease this kit installation. The following
procedure leaves the engine installed in the vehicle.

3.

Disconnect both battery terminals.

4.

Disconnect the brake cooling hose from the ducting located between engine and transmission. Snip the tie-wrap
that is securing the hose and move it clear of the work area.

HDi vehicles do not have a brake cooling fan and therefore no brake cooling hose to disconnect.
5.

Remove the plastic shrouding that covers the engine flywheel.

6.

Remove the (4) fasteners securing the engine fan belt and pulley at the flywheel. Photo 1 Exercise caution
when re-installing this pulley to ensure all shims are present. Leave the Kohler fan belt attached to the top
pulley at the fan blade. The lower end of the belt hangs loose for now.

7.

Re-install the Kohler pulley (along with shims) and the supplied 850-59 V-Belt Pulley using (4) 112-167 Bolts
and (4) 108-05 Lockwashers. The V-Belt Pulley must sit on top and flat against the flywheel pulley for proper
alignment. Tighten the bolts securely. (Torque to 14ft.lbs.) Do NOT over-tighten! Photo 2 & 3

The pulleys must be installed and torqued to the flywheel BEFORE the engine fan belt is reinstalled.
DO NOT attempt to install the pulleys to the engine flywheel with the V- Belt installed between the
sheaves. The belt MUST be fed on AFTER the pulleys are installed and torqued.
2

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Photo 1

Photo 2

Photo 3
Photo 4
8. While turning the engine flywheel, feed the fan belt over the 850-59 V-belt Pulley and then back up onto the
engine flywheel pulley. Photo 4
9.

Attach the 850-181 Bracket to the bottom of the engine block. Photo 5 Torque to 14ft.lbs.

10. Attach the 850-180 Bracket to the lower rad bracket. Remove the existing screws and replace with the ones
shown in the illustrated parts manual. Photo 6 Torque to 60 in.lbs.

Photo 5

Photo 6

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11. Reaching in from the firewall, loosely attach the 850-41 Alternator to the 850-181 Bottom Bracket Assembly
using one (1) 112-22 Bolt, (1) 108-27 Lockwasher and (1) 117-62 Nut. Photo 7 See illustration on parts list.
12. Loosely attach the ear of the alternator to the 850-180 Upper Bracket using a 112-63 Bolt slipped through a
108-05 Lockwasher, 108-24 Flat Washer and the 850-52 Block Adjuster. Photo 8 Install the 850-45 V Belt
around both pulleys at the same time.

Photo 7

Photo 8

13. Place a 108-03 Lockwasher to the 112-65 Belt Adjustment Bolt. Slip it through the tab hole on the alternator
adjustment bracket and thread it into the 850-52 Adjustor Block. Thread the 112-65 Adjustment Bolt until
the V-belt is tensioned. The V-belt should be tightened enough that it deflects no more then 1/8" with approx.
6 lbs. of force. Photo 9.
14. Using the 13mm socket, tighten the previously finger tight 112-63 bolt. Photo 10

Photo 9

Photo 10

15. Using the 17mm socket tighten the 117-62 nut. Photo 7 Re-check V-belt tension and re-adjust if necessary.
Tighten the 112-65 screw so that it doesnt back out.
16. Re-install the brake cooling hose and tie-wrap away from any moving parts. NOTE: N/A to HDi models.

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Wiring:
17. Disconnect the original Kohler voltage regulator at
the plug. Tie-wrap the plug securely away from any
contact with the engine.
18. Locate the 850-58 Alternator Wire Harness. Attach
the plug end with the yellow wire into the alternator.
Photo 11 Open the engine hood area and locate the
open green wire in the main wire harness with the
female blade terminal (this open terminal is for the
windshield wiper assessory). You may have to unclip
the main harness from the nylon clip(s) securing
Photo 11
the wire harness up under the dash. This terminal
is found approximately near the center of the wire
harness. Clamp the supplied 118-04 T-Tap connector to this green wire and plug the bullet connector of the
850-58 Alternator Wire Harness into the T-Tap connector.
19. Attach the heavy 6 gauge wire to the post on the alternator followed by the 117-94 Insulated Push Nut and
rubber boot). Attach the other end to the post on the starter solenoid (older models). This is the same terminal
at which there is a purple charging wire attached.

Later model Argos utilize a remote 613-123 power post located on the hood frame at the front of the
vehicle. In this case attach the 6 gauge wire here. Photo 12

Photo 12

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20. Place the supplied 10 Amp fuse into the fuse block D Slot indicated as wiper accessory.
21. Reconnect the battery. Make sure terminals are connected to the correct battery posts.
22. Use tie-wraps to securely fasten the 850-58 wire harness. Secure it to the steering tube and along the engine
ground wire that connects to the vehicle ground strip. The 850-58 wire harness should be secured in such a way
as to prevent the wires from getting caught in the flywheel, brake disk and drive chains.
23. Reconnect the brake cooling hose to the brake duct and tie-wrap to ensure it does not come into any contact
with the engine flywheel or other moving engine parts.
24. Test alternator by running engine and watching voltmeter. Meter reading should increase when engine speed
is increased. Re-install hood and firewall.

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