The following is a write up on how to install a Mercury Villager alternator onto your KA24(D)E, courtesy of two4dsx
Simply put, you can use an alternator from the 95-98 Mercury Villagers.
(110amps and half the price of the ka24e and de alternators)
What needs modified:
Quite simple. If you have a drill and a 3/8" drill bit, you are good to go.
The mounting bracket inner diameter on the Villager is slighty smaller. Basically what you need to do is drill out both sides of the bracket to 3/8". That way you can also use the stock ka bolt..
As for the connection, its the same, so thats a good thing. One less worry...
Only other thing you need to drill out is the little ground connector on the harness(the fat white wire leads to). If you look at the Villager alternator you will notice the larger diameter bolt coming out the back.
Mounting is almost as simple as installing a stock ka alternator. The only thing you may have do is losten the bolts holding the tensioner bracket to the engine in order to get the alternator up high enough to get the belt around the pulley.
Only difference between the pulleys are the ribs. The Villager alt. has 4 ribs instead of 3. Just use the 3 inner ribs of the pulley.
Thanks about it.
(total time with install about 30 minutes)
If you are having any troubles with the install fell free to send me a pm
Thank you