Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Alternator

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TESTING



Current Output Test
1986-95 MODELS

See Figures 1 through 7

The current output test decides whether the alternator can deliver its rated current output.

  1. Before starting any tests, make sure that the vehicle has a fully charged battery. For more information on charging the battery, refer to Routine Maintenance .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Detach the output wire from the B+ terminal on the alternator.
  6.  
  7. Connect a 0-150 amp scale (DC) ammeter in series between the B+ terminal and the output wire. Connect the positive lead to the B+ terminal and the negative lead to the output wire.
  8.  



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Fig. Fig. 1: Alternator terminal identification and locations-1991-95 models



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Fig. Fig. 2: Alternator current output test wiring schematic-1991-95 models

  1. Using a 0-18 volt minimum voltmeter, connect the positive lead to the B+ terminal and the negative lead to a good ground.
  2.  
  3. Connect an engine tachometer to the engine. Refer to the tachometer manufacturer's instructions.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Connect a volt/amp tester equipped with a variable carbon pile rheostat between the battery terminals. Be sure the carbon pile is OFF before connecting the leads.
  8.  
  9. If necessary, remove the fresh air hose between the PCM and the air cleaner.
  10.  



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Fig. Fig. 3: Alternator current output test schematic-1989-90 models



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Fig. Fig. 4: Alternator current output test schematic-1986-88 models with internal voltage regulators, and 1989 2.2L Turbo II models

  1. For 1988-95 models and 1986-87 models with internal voltage regulators, full field the alternator by connecting a jumper wire between a good ground and the K20 (1991-95 models) or R3 (1986-90 models) circuit terminal at the back of the alternator (refer to the generator output test diagram).
  2.  


WARNING
Do not connect the A142 (1991-95 models) or blue J2 (1986-90 models) circuit terminal to ground; the fusible link will burn.

  1. For 1986-87 models with external voltage regulator, detach the wiring harness connector from the Electronic Voltage Regulator (EVR) on the vehicle. Attach a jumper wire from the EVR wiring harness connector green wire (outside terminal) to ground.
  2.  



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Fig. Fig. 5: Alternator terminal identification and locations-1981-88 models with External Voltage Regulators (EVR)



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Fig. Fig. 6: Alternator output test schematic-1981-88 models with EVRs



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Fig. Fig. 7: EVR wiring terminal identification and locations-1981-88 models


WARNING
Do not ground the blue J2 lead of the wiring connector. Do not spread the connector terminals with the jumper wire.

  1. Start the engine. Immediately after starting, reduce the engine speed to idle.
  2.  
  3. Adjust the carbon pile and engine speed in steps until an engine speed of 1250 rpm, and a voltage reading of 15 volts is obtained.
  4.  


WARNING
Do not allow the battery voltage to exceed 16 volts.

  1. The alternator amperage must meet the MINIMUM output requirements for the particular alternator being tested, as follows:
  2.  

1991-95 Models:


Bosch 90 HS, ID No. 4557431-84 amp
 
Bosch 90 RS, ID No. 5234231-88 amp
 
Denso 75 HS, ID No. 4557301-68 amp
 
Denso 90 HS, ID No. 5234031-86 amp
 

1990 Models:


Bosch 90 RS, ID No. 5234208-75 amp
 
Denso 75 HS, ID No. 4557301-68 amp
 
Denso 90 HS, ID No. 5234031-87 amp
 
Denso 120 HS, ID No. 5234208-98 amp
 
Denso 120 HS, ID No. 5234231-98 amp
 

1989 Models:


Bosch 90 RS, ID No. 5233718-75 amp
 
Denso 75 HS, ID No. 5233416-68 amp
 
Denso 90 HS, ID No. 5233418-87 amp
 
Denso 120 HS, ID No. 5233608-98 amp
 

1988 Models:


Bosch 35/75 Amp, ID No. 5227469-30 amp
 
Bosch 40/90 Amp, ID No. 5227474-40 amp
 
Chrysler 40/90 Amp, ID No. 5233474-87 amp
 
Chrysler 50/120 Amp, ID No. 5233508-98 amp
 

1986-87 Models:


Bosch 40/90 Amp, ID No. 5226600-80 amp
 
Chrysler 78 Amp External Voltage Regulator, ID No. 5213763-56 amp
 
Chrysler 78 Amp Internal Voltage Regulator, ID No. 5226135-56 amp
 
Chrysler 40/90 Amp, ID No. 5227100-87 amp
 
Chrysler 50/120 Amp, ID No. 5226457-98 amp
 

1981-85 Models:


Mitsubishi (2.6L engines)-63-70 amps
 
Bosch, ID No. B120 427 850 MP-78-85 amps
 
Bosch w/external Chrysler regulator, ID K1-50 amp
 
Bosch 40/90 Amp (1985 models)-87 amp
 
Chrysler w/external Chrysler regulator, yellow ID tag-45 amp
 
Chrysler w/external Chrysler regulator, brown ID tag-56 amp
 
Chrysler 40/90 Amp (1985 models)-96 amp
 

  1. If the amperage reading is less than specified the alternator should be replaced with a new one. These alternators are not intended to be disassembled for service. It must be replaced as an assembly.
  2.  
  3. After the current output test is completed, reduce the engine speed, turn off the carbon pile and turn the ignition switch OFF .
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the ammeter, voltmeter, tachometer and carbon pile.
  8.  
  9. Remove the jumper wire between the K20 or R3 circuit terminal and ground.
  10.  
  11. Reconnect the output wire to the B+ alternator terminal.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. If necessary, install the fresh air hose.
  16.  

REMOVAL & INSTALLATION



See Figures 8, 9, 10, 11, 12, 13, 14, 15, 16 and 17



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Fig. Fig. 8: Exploded view of 2.2L (non-turbocharged versions) and 2.5L engines' alternator mounting



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Fig. Fig. 9: Exploded view of 2.2L Turbo 16 valve engines' alternator mounting



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Fig. Fig. 10: Engine wiring harness connectors for a common Bosch alternator



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Fig. Fig. 11: Alternator wiring connector identification and location for a common Denso alternator



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Fig. Fig. 12: After removing the A/C compressor, loosen the alternator wiring connectors ...



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Fig. Fig. 13: ... then pull the wiring connectors off of the alternator



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Fig. Fig. 14: Remove the adjusting bolt, then loosen the pivot bolt and nut ...



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Fig. Fig. 15: ... remove the nut and washer from the pivot bolt and ...



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Fig. Fig. 16: ... slide the pivot bolt out while holding the alternator from falling



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Fig. Fig. 17: Remove the alternator from the engine compartment-1986 2.2L engine shown

  1. Disconnect the negative battery terminal.
  2.  
  3. If necessary for access to the alternator, remove the A/C drive belt and compressor. Remove the compressor from the mounting bracket and set aside without disconnecting the A/C refrigerant lines. For more information, refer to Chassis Electrical .
  4.  
  5. Remove the alternator drive belt. For more information, refer to Routine Maintenance .
  6.  
  7. Remove the wire connector hold-down nuts and plug-in connectors from the rear of the alternator housing.
  8.  
  9. Remove the 2 alternator mounting bolts and position the alternator to gain access to all the wire connectors.
  10.  
  11. Remove the alternator from the vehicle.
  12.  

To install:
  1. Position the alternator in the engine compartment so that the wiring connectors can be attached to the rear of the alternator housing. Tighten the alternator field terminal nuts to 25 inch lbs. (3 Nm) and the B+ and ground terminal nuts to 75 inch lbs. (9 Nm).
  2.  
  3. Once the alternator wiring is attached, position the alternator against the alternator mounting bracket.
  4.  
  5. Install and tighten the mounting bolts and nuts to 40 ft. lbs. (54 Nm).
  6.  
  7. Install and properly tension the alternator drive belt. For more information, refer to Routine Maintenance .
  8.  
  9. If removed, install the A/C compressor and drive belt. Refer to Chassis Electrical for the proper A/C installation procedures. Properly tension the A/C compressor drive belt, as described in Routine Maintenance .
  10.  
  11. Connect the negative battery cable.
  12.  

 
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