Painless Performance Alternator - Painless PowerStar

In the overall picture, taking the time to remove or reposition parts that deter access to removing the alternator (as opposed to creating forced clearance between other parts) will pay off with a cleaner job and better results.

There are only two bolts that hold the alternator on. The top bolt is around 1 1/2 inches long, and the bottom bolt is much longer (I forgot to measure it), spanning the distance from the alternator's face to beyond the alternator's rear face and extending into the engine block. Our fan belt was new, but if yours isn't, this is the time to replace it.

It is always a good idea to compare the old part with the new one before attempting to install it. The only outward physical difference between our old alternator and the new Painless PowerStar was the old rebuild's threaded ear to retain the lower mounting spacer.

We cleaned the lower spacer with an ecologically friendly solvent, and then checked the factory-original GM lower spacer for fitment to the Painless PowerStar.

Upon checking the lower mounting bolt to see if it would fit, we discovered the Painless PowerStar alternator comes with a sleeve-type bushing to guarantee a tight fit. In our case, the bushing was too tight and had to be drifted out before installation.

The final step before installing the PowerStar alternator into place on the '79 was to completely assemble it and make any last-minute checks. We discovered the threads on the mounting bolt were slightly crossed. We chased the threads with a die nut and coated them with white lithium grease.

The PowerStar alternator features a unique adjustable voltage regulator with a range of 13.5-18.5 volts. It is adjusted by turning this little Phillips head screw while observing a voltage meter (on board or handheld).

For most C-10 applications, the PowerStar alternator is a true one-wire system that only requires the main 12-volt lead (A). That said, the plug (B) with the red and black wires that we unhooked from the rebuilt alternator did not have to be reconnected to the PowerStar alternator.

It can't be stressed enough that checking to make sure things are right before final tightening occurs will ensure a perfect installation. Notice the encircled area reveals a gap between the stock mounting bracket and the PowerStar alternator. A common mistake would be to overtighten the mounting bolt to adjust for this. At best, the pulleys wouldn't run true and there would be premature bearing wear or an electrical failure.