Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Alternator

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Diagnosis & Testing




CAUTION
Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Check the following before the test.

    Alternator installation
     
    Alternator drive belt tension
     
    Fusible link
     
    Abnormal noise from the alternator while the engine is running
     

  4.  
  5. Turn the ignition switch to the LOCK (OFF) position.
  6.  
  7. Disconnect the negative battery cable and isolate to prevent accidental reconnection.
  8.  
  9. Disconnect the alternator output wire from the alternator "B" terminal and connect a DC test ammeter with a range of 0-100 A in series between the "B" terminal and the disconnected output wire.
    NOTE
    Connect the positive lead of the ammeter to the "B" terminal and connect the negative lead of the ammeter to the disconnected output wire.


    NOTE
    Use of a clamp-type ammeter which enables measurements to be taken without disconnecting the alternator output wire is advisable and recommended.



    Click image to see an enlarged view

    Fig. Hookup schematic for alternator test

  10.  
  11. Connect a digital-type voltmeter between the alternator "B" terminal and the positive battery terminal.
    NOTE
    Connect the positive lead of the voltmeter to the "B" terminal and the negative lead of the voltmeter to the positive battery cable.

  12.  
  13. Reconnect the negative battery cable.
  14.  
  15. Connect an engine tachometer or scan tool MB991502.
  16.  
  17. Leave the hood open.
  18.  
  19. Start the engine.
  20.  
  21. With the engine running at 2,500 rpm, turn the headlights and other lights on and off to adjust the alternator load so that the value displayed on the ammeter is slightly above 30 A.
    NOTE
    When the alternator output is high and the value displayed on the ammeter does not decrease to 30 A, set the ammeter's range to 40 A.



    Limit value: maximum 0.3 V
     

  22.  
  23. Read the value displayed on the voltmeter at this time. In this case the limit value becomes maximum 0.4 V.
  24.  
  25. Adjust the engine speed by gradually decreasing it until the value displayed on the ammeter is 30 A.
  26.  
  27. Take a reading of the value displayed on the voltmeter at this time.
  28.  
  29. If the value displayed on the voltmeter is above the limit value, there is probably a malfunction in the alternator output wire.
    1. Check the wiring between the alternator "B" terminal and the positive battery terminal, including the fusible link. If a terminal is not sufficiently tight or if the harness has become discolored due to overheating, repair and test again.
    2.  

  30.  
  31. After the test, run the engine at idle.
  32.  
  33. Turn off all lights and turn the ignition switch to the "LOCK" (OFF) position.
  34.  
  35. Disconnect the engine tachometer or scan tool MB991502.
  36.  
  37. Disconnect the negative battery cable.
  38.  
  39. Disconnect the ammeter and voltmeter and engine tachometer.
  40.  
  41. Connect the alternator output wire to the alternator "B" terminal.
  42.  
  43. Connect the negative battery cable.
  44.  

Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
     
    Field circuit from alternator.
     
    B+ terminal cover by spreading the cover with a small flat blade tool.
     
    B+ terminal nut and wire
     

  4.  
  5. Loosen adjusting T-bolt, but do not remove
  6.  
  7. Loosen pivot bolt, but do not remove.
  8.  
  9. Loosen adjusting bolt to allow removal of the alternator drive belt.
  10.  
  11. Continue by removing the following:

    Adjusting T-bolt.
     
    Pivot bolt, do not drop spacer.
     

  12.  
  13. Release alternator from mounting bracket and move it toward passenger head lamp bucket.
  14.  
  15. Remove alternator from head lamp bucket area.

    Click image to see an enlarged view

    Fig. Exploded view of the alternator and related components-2.0L engine



    Click image to see an enlarged view

    Fig. View of the auto-cruise speed control and related components-2.0L and 2.5L engines

  16.  

To install:

  1. Install or connect the following:

    Alternator
     
    Alternator bracket
     
    Alternator electrical connectors
     
    Alternator drive belt
     

  2.  
  3. Attach a belt tension gauge midway on the drive belt; then, adjust the drive belt tension to 90-110 lbs. (400-490 N) for a used belt or 110-160 lbs. (490-712 N) for a new belt.
  4.  
  5. If installing a new belt, tension the belt to 70 lbs. (310 N) and operate the engine for 5 minutes or more; then, apply the final tension.
  6.  
  7. Torque the alternator-to-lower alternator bracket nut to 45 ft. lbs. (61 Nm) and the alternator-to-upper bracket bolt to 40 ft. lbs. (54 Nm).
  8.  
  9. Install or connect the following:

    Auto-cruise speed control assembly
     
    Wheel well side cover
     
    Right front wheel
     
    Negative battery cable
     

  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable from the shock tower
     
    Belt cover
     
    Alternator electrical connectors
     
    Alternator adjusting and pivot bolts, loosen them
     
    Alternator drive belt
     
    Alternator adjusting and pivot bolts, do not drop the pivot bolt-s spacer
     
    Alternator, by moving it toward the headlight bucket area
     

  4.  

To install:

  1. Install or connect the following:

    Alternator
     
    Alternator drive belt
     

  2.  
  3. Using a Belt Tension Gauge, adjust the drive belt tension to 80 lbs. (109 Nm) for a used belt or to 150 lbs. (203 Nm) for a new belt.
  4.  
  5. Install or connect the following:

    Alternator adjusting and pivot bolts. Torque the bolts to 40 ft. lbs. (54 Nm).
     
    Alternator electrical connectors
     
    Belt cover
     
    Negative battery cable to the shock tower
     

  6.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    The negative battery cable from the shock tower
     
    The accessory drive belt cover
     
    The alternator electrical connectors
     
    The accessory drive belt splash shield
     
    The accessory drive belt
     
    The Manifold Absolute Pressure (MAP) sensor from the intake manifold
     
    The alternator bolts
     
    The alternator

    Click image to see an enlarged view

    Fig. Exploded view of the alternator and related components-2.4L engine

     

  4.  

To install:

  1. Install or connect the following:

    The alternator and torque the bolts to 33 ft. lbs. (44 Nm)
     
    The MAP sensor
     
    The accessory drive belt and splash shield
     
    The alternator electrical connectors
     
    The accessory drive belt cover
     
    The negative battery cable
     

  2.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable from the shock tower
     
    Accessory belt splash shield and loosen the belt
     
    Alternator electrical connectors
     
    A/C pressure switch and clutch electrical connectors
     
    Engine oil dipstick
     
    Alternator
     

  4.  

To install:

  1. Install or connect the following:

    Alternator and torque the bolts to 40 ft. lbs. (54 Nm)
     
    Engine oil dipstick tube
     
    A/C pressure switch and clutch electrical connectors
     
    Alternator electrical connectors
     
    Drive belt and splash shield
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise vehicle and support.
  4.  
  5. Remove the accessory drive belt splash shield.
  6.  
  7. Loosen the accessory drive belt.
  8.  
  9. Remove the lower mounting bolt.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the electrical connections from the alternator.
  14.  
  15. Disconnect the electrical connector to the A/C pressure switch and A/C clutch.
  16.  
  17. Remove the engine oil dip stick.
  18.  
  19. Remove the 2 upper mounting bolts.
  20.  
  21. Remove the alternator.
  22.  

To install:

  1. Install the alternator.
  2.  
  3. Install the 2 upper bolts, but do not tighten.
  4.  
  5. Install the engine dip stick tube.
  6.  
  7. Connect the A/C pressure switch and A/C clutch electrical connectors.
  8.  
  9. Connect the electrical connections to the alternator.
  10.  
  11. Raise vehicle and support.
  12.  
  13. Install the lower bolt. Tighten bolt to 40 ft. lbs. (54 Nm).
  14.  
  15. Install the accessory drive belt.
  16.  
  17. Install the accessory drive belt splash shield.
  18.  
  19. Lower the vehicle.
  20.  
  21. Install the 2 upper mounting bolts. Tighten bolts to 40 ft. lbs. (54 Nm).
  22.  
  23. Connect the negative battery cable.
  24.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Remove or disconnect the following:

    Engine under cover
     
    Engine mount bracket
     
    Drive belt
     
    Alternator belt
     
    Oil level gauge unit
     
    Alternator electrical connectors
     
    Alternator brace
     
    Alternator
     

  6.  

Testing



The alternator provides power consuming components with current while the engine is running and maintains battery charge. The alternator is mounted on the front edge of the engine. The output of the alternator depends on engine speed. When the engine is idling, the alternator operates at approximately half of its maximum output. When the engine is idling with many power consuming components engaged, the alternator may be unable to maintain full battery charge.

The alternator creates an alternating current which is converted to a direct current in the rectifier bridge. The alternator also utilizes a built-in voltage regulator.

  1. Check that the wiring is in good condition.
  2.  
  3. Check for any abnormal noise from the alternator while the engine is running. Noise emitting from the alternator may be caused by:

    Worn, loose or defective bearings
     
    Loose or defective drive pulley
     
    Incorrect, worn, damaged, or misadjusted drive belt
     
    Loose mounting bolts
     
    Misaligned drive pulley
     
    Defective stator or diode
     
    Damaged internal fins
     

  4.  
  5. Check the accessory drive belt for wear or slipping.
  6.  
  7. With the engine running at 2,500 RPM, headlights on and fan blower on high:
    1. The alternator output voltage should be 14.0 volts plus or minus 0.5 volts at 68°F.
    2.  
    3. The alternator test amperage should be 135 Amps.
    4.  

  8.  

 
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