Chrysler Front Wheel Drive Cars 6-CYL 1988-1995 Repair Information

Alternator

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REMOVAL & INSTALLATION



3.0L Engines
EXCEPT PREMIER AND MONACO

See Figures 1 through 10

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Remove the alternator drive belt (refer to General Information & Maintenance ).
  4.  
  5. Remove the alternator mounting bolts and separate the alternator from the mounting bracket.
  6.  
  7. Remove the B+ terminal nut, field terminal nuts, and the ground/wire harness hold-down nuts. Remove the wire connectors.
  8.  
  9. Remove the alternator from the vehicle.
  10.  



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Fig. Fig. 1: Alternator removal and installation orientation-3.0L engines, except Premier and Monaco



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Fig. Fig. 2: Electrical wiring harness connections of the Bosch alternator-3.0L engines, except Premier and Monaco



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Fig. Fig. 3: Electrical wiring harness connections of the Nippondenso alternator-except Premier and Monaco

To install:
  1. Attach the wiring and electrical connections to the alternator, making sure to include all of the wires, nuts and bolts. Tighten the B+ terminal and ground terminal nuts to 75 inch lbs. (9 Nm) and the field terminal nuts to 25 inch lbs. (3 Nm).
  2.  
  3. Mount the alternator to the brackets with the nuts and bolts. Tighten the two mounting bolts and nuts to 40 ft. lbs. (54 Nm).
  4.  
  5. Install the drive belt and attach the negative (-) battery cable.
  6.  



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Fig. Fig. 4: Rotate the accessory drive belt tensioner clockwise, and slip the belt off the pulley



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Fig. Fig. 5: Once the drive belt is removed, remove and identify (label) the rear mounting bolt ...



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Fig. Fig. 6: ... then remove the front mounting bolt, using a box end wrench and ratchet wrench



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Fig. Fig. 7: With both mounting bolts removed, lift and rotate the alternator to access the wiring connector



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Fig. Fig. 8: Take note of (or label) the electrical connections on the back of the alternator, then ...



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Fig. Fig. 9: ... loosen and remove the connectors' hold-down nuts ...



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Fig. Fig. 10: ... and lift the wiring harness off of the alternator-the alternator can now be removed

PREMIER AND MONACO

See Figures 11 and 12

This procedure requires raising and supporting the vehicle. Jackstands and a floor jack will be needed.

  1. Disconnect the battery negative (-) cable.
  2.  
  3. Raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Remove the lower splash shield from under the car.
  6.  
  7. Unplug the alternator electrical wiring harness connector.
  8.  
  9. Relieve the tension of the drive belt by turning the adjusting bolt and loosening the mounting and pivot bolts.
  10.  



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Fig. Fig. 11: Alternator removal and installation components-3.0L Premier and Monaco engines



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Fig. Fig. 12: Tighten the alternator bolts to the torque shown-3.0L Premier and Monaco engines

  1. Remove the drive belt from the alternator pulley. Complete removal from the vehicle of the drive belt is not necessary.
  2.  
  3. Remove the mounting and pivot bolts. Be careful, the alternator is now loose and can fall from its position. Lower the alternator out of the vehicle.
  4.  

To install:
  1. Position and hold the alternator in its mounting position. Install and loosely tighten the mounting and pivot bolts.
  2.  
  3. Install the drive belt onto the alternator pulley. Make certain that the belt is correctly seated on the pulley.
  4.  
  5. Install a belt tension gauge in the middle of a belt span. Ensure that the tension gauge is not touching any engine component. Tighten the adjusting bolt on the alternator bracket until the correct belt tension is obtained:

    New belt-180-200 lbs. (800-900 N)
     
    Used belt-140-160 lbs. (623-712 N)
     

  6.  
  7. If a belt gauge is not available, tighten the adjusting nut until the belt only deflects 1 / 4 - 1 / 2 in. (6-12mm) on its longest side. Refer to General Information & Maintenance for more in depth belt procedures.
  8.  
  9. Tighten the alternator pivot bolt to 37 ft. lbs. (50 Nm) and the mounting bolt to 20 ft. lbs. (27 Nm). After tightening the mounting bolt, recheck the torque of the pivot bolt.
  10.  
  11. Double check the belt to make certain it is seated correctly on the pulley. Make sure all of the wires and bolts are in place and tightened.
  12.  
  13. Install the splash shield.
  14.  
  15. Lower the vehicle.
  16.  
  17. Connect the negative (-) battery cable.
  18.  

3.3L and 3.8L Engines

See Figures 3, 13 and 14

  1. Disconnect the battery negative (-) cable.
  2.  
  3. Remove the alternator drive belt. Refer to General Information & Maintenance for this procedure.
  4.  
  5. Loosen, but do not remove the nut on the support bracket at the exhaust manifold.
  6.  
  7. Remove the alternator tensioner power steering bracket bolt.
  8.  
  9. Remove the tensioner stud nut and the tensioner.
  10.  
  11. Remove the alternator mounting bolts.
  12.  
  13. Remove the power steering reservoir from the alternator mounting bracket.
  14.  
  15. Remove the 3 alternator support bracket bolts.
  16.  
  17. Remove the intake plenum to generator mounting bracket bolt.
  18.  
  19. Remove the alternator support bracket.
  20.  
  21. Position the alternator to gain access to the wiring and remove the wiring from the alternator.
  22.  
  23. Extract the alternator from the vehicle.
  24.  



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Fig. Fig. 13: Loosen, but do not entirely remove the support bracket from the engine-3.3L and 3.8L engines



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Fig. Fig. 14: Alternator removal and installation orientation-3.3L and 3.8L engines

To install:
  1. Attach the wiring to the alternator. Make certain the correct wires go to the correct terminals.
  2.  
  3. Install the alternator support bracket. Tighten all bracket and alternator (except for the wiring nuts) bolts to 40 ft. lbs. (54 Nm).
  4.  
  5. Install the intake plenum to alternator mounting bracket bolt.
  6.  
  7. Install the 3 alternator support bracket bolts.
  8.  
  9. Mount the power steering reservoir onto the alternator mounting bracket.
  10.  
  11. Install the alternator mounting bolts, remember to tighten all bracket and alternator bolts to 40 ft. lbs. (54 Nm).
  12.  
  13. Install the tensioner stud nut and the tensioner itself. Install the alternator tensioner power steering bracket bolt.
  14.  
  15. Tighten the nut on the support bracket at the exhaust manifold.
  16.  
  17. Install the drive belt onto the alternator pulley. Make certain that the belt is seated correctly on the pulley. Refer to General Information & Maintenance for further belt adjusting procedures.
  18.  
  19. Connect the negative (-) battery cable.
  20.  

 
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