Chrysler Neon 1995-1999 Repair Guide

Alternator

Print

TESTING



Voltage Drop Test
1995 VEHICLES

See Figure 1

The alternator output wire voltage drop test shows the amount of voltage drop across the alternator output wire between the alternator B+ terminal and the battery positive post.

  1. Before beginning the test, make sure the vehicle has a fully charged battery.
  2.  
  3. Using an ohmmeter, check the alternator ground path. Resistance between the alternator housing to the engine should not exceed 0.3 milliohms. If the resistance is higher, clean the surfaces between the alternator and the mounting bracket thoroughly and make sure all fasteners are tightened to the proper specifications.
  4.  
  5. Using a 0-6 volt scale voltmeter, connect the positive lead to the alternator (B+) output terminal. Connect the negative lead to the battery positive post.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Alternator wiring connection locations-1995 vehicles

  1. Connect an engine tachometer, according to the manufacturers directions.
  2.  
  3. Make sure the parking brake is fully engaged.
  4.  
  5. Place the transaxle in Neutral, then start the engine. Let the engine warm up for about 2 minutes.
  6.  
  7. Operate the blower motor on high speed.
  8.  
  9. Turn the headlight high beams on.
  10.  
  11. Increase the engine speed to about 2,400 rpm.
  12.  
  13. Check the voltmeter, the reading should not be over 0.8 volts. If a higher voltage is shown, inspect, clean and tighten all connections between the alternator B+ terminal and the battery positive post.
  14.  

A voltage drop test can be performed at each connection to find a connection with excessive voltage drop.

  1. If the voltage drop tests are OK, reduce the engine speed, turn off the headlights and blower motor, then turn the ignition OFF .
  2.  

1996-99 VEHICLES

See Figure 1

These tests will show the amount of voltage drop across the alternator output wire from the alternator output (B+) terminal to the battery positive post. They will also show the amount of voltage drop from the ground (-) terminal on the alternator.

A voltmeter with a 0-6 volt DC scale should be used for these tests. By repositioning the voltmeter test leads, the point of high resistance (voltage drop) can easily be found. Test points on the alternator can be reached by either removing the air cleaner housing or below by raising the vehicle.

  1. Before starting the test, make sure the battery is in good condition and is fully charged. Check the conditions of the battery cables.
  2.  
  3. Start the engine, let it warm up to normal operating temperatures, then turn the engine OFF .
  4.  
  5. Connect an engine tachometer, following the manufacturers directions.
  6.  
  7. Make sure the parking brake is fully engaged.
  8.  
  9. Start the engine, then place the blower on High, and turn the high beams interior lamps On.
  10.  
  11. Bring the engine speed up to 2,400 rpm and hold there.
  12.  
  13. To test the ground (-) circuitry, perform the following:
    1. Touch the negative lead of the voltmeter directly to the positive battery post.
    2.  
    3. Touch the positive lead of the voltmeter to the B+ output terminal stud on the alternator (NOT the terminal mounting nut). The voltage should be no higher than 0.6 volts. If the voltage is higher than 0.6 volts, touch the test lead to the terminal mounting stud nut, and then to the wiring connector. If the voltage is now below 0.6 volts, look for dirty, loose or poor connections at this point. A voltage drop test may be performed at each ground (-) connection in the circuit to locate the excessive resistance.
    4.  

  14.  
  15. To test the positive (+) circuitry, perform the following:
    1. Touch the positive lead of the voltmeter directly to the negative battery post.
    2.  
    3. Touch the negative lead of the voltmeter to the ground terminal stud on the alternator case (NOT the terminal mounting nut). The voltage should be no higher than 0.3 volts. If the voltage is higher than 0.3 volts, touch the test lead to the terminal mounting stud nut, and then to the wiring connector. If the voltage is now below 0.3 volts, look for dirty, loose or poor connections at this point. A voltage drop test may be performed at each positive (+) connection in the circuit to locate the excessive resistance.
    4.  

  16.  
  17. This test can also be performed between the alternator case and the engine. If the test voltage is higher than 0.3 volts, check for corrosion at the alternator mounting points or loose alternator mounting.
  18.  

Output Voltage Test

1995 VEHICLES

See Figures 2, 3, 4, 5, 6 and 7

The output voltage test determines whether or not the alternator is capable of delivering output current to satisfy the vehicle electrical load requirements.

  1. Before starting the test, make sure the vehicle has a fully charged battery.
  2.  
  3. Connect voltmeter leads across battery terminals, as shown in the accompanying figure.
  4.  
  5. Record base battery voltage which is with all electrical loads and the ignition switch OFF .
  6.  
  7. Fully engage the parking brake, then make sure the transaxle in Park (A/T) or Neutral (M/T).
  8.  



Click image to see an enlarged view

Fig. Fig. 2: Output voltage test wiring schematic-1995 vehicles

  1. Using a jumper wire, attach a jumper wire from K20 terminal to ground, as shown in the accompanying figures.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Electrical resistance test-1995 vehicles



Click image to see an enlarged view

Fig. Fig. 4: Powertrain control module connector-1995 vehicles



Click image to see an enlarged view

Fig. Fig. 5: Battery voltage test connections-1995 vehicles

  1. Start the engine and allow to warm up to normal operating temperatures.
  2.  
  3. With the engine at operating temperatures, record the battery voltage at engine speed of 1,800 rpm with no other electrical loads. The battery voltage should not be more than 2.7 volts above the base battery voltage. If battery voltage is higher than 2.7 volts, refer to the Overcharge test.
  4.  



Click image to see an enlarged view

Fig. Fig. 6: Overcharge test-1995 vehicles

  1. Record the battery voltage with the engine at 2,400 rpm and the following conditions:

    A/C blower motor on High, if equipped.
     
    Heater blower motor on High.
     
    Headlights on high beam.
     

  2.  
  3. The battery voltage should be a minimum of 0.4 volts above base battery voltage. If the battery voltage is below 0.4 volts, refer to the Low or No Voltage Test.
  4.  



Click image to see an enlarged view

Fig. Fig. 7: Low or no voltage test-1995 vehicles

  1. After the output voltage tests are finished, turn off the blower motor and headlights, then turn the ignition switch OFF .
  2.  

1996-99 VEHICLES
  1. Determine if any DTC's exist, as outlined in Driveability & Emissions Controls .
  2.  
  3. Before starting the test, make sure the battery is in good condition and is fully charged. Check the conditions of the battery cables.
  4.  
  5. Perform the voltage drop test to ensure clean and tight alternator/battery electrical connections.
  6.  
  7. Be sure the alternator drive belt is properly tensioned, as outlined in General Information & Maintenance .
  8.  
  9. A volt/amp tester equipped with both a battery lad control (carbon pile rheostat) and an inductive-type pickup clamp (ammeter probe) will be used for this test. Make sure to follows all directions supplied with the tester. If you are using a tester equipped with an inductive-type clamp, you don't have to remove the wiring from the alternator.
  10.  
  11. Start the engine and let run until it reaches normal operating temperature, then shut the engine OFF .
  12.  
  13. Make sure all electrical accessories and lights are turned off.
  14.  
  15. Connect the volt/amp tester leads to the battery. Be sure the carbon pile rheostat control is in the OPEN or OFF position before connection the leads.
  16.  
  17. Connect the inductive camp (ammeter probe), following the instructions supplied with the test equipment.
  18.  
  19. If a volt/amp tester is not equipped with an engine tachometer, connect a separate tachometer to the engine.
  20.  
  21. Fully engage the parking brake.
  22.  
  23. Start the engine, then bring the engine speed up to 2,500 rpm.
  24.  


WARNING
This load test must be performed within 3 seconds to prevent damage to the test equipment!

  1. With the engine speed held at 2,500 rpm, slowly adjust the rheostat control (load) on the tester to get the highest amperage reading. Do not let the voltage drop below 12 volts. Record the reading. On certain brands of test equipment, this load will be applied automatically. Make sure to read the operating guide supplied with test equipment.
  2.  
  3. The ammeter reading must meet the minimum test amps specification which is 75 amps.
  4.  
  5. Rotate the load control to the OFF position.
  6.  
  7. Continue holding the engine speed at 2,500 rpm. If the EVR circuitry is OK, the amperage should drop below 3-20 amps. With all of the electrical accessories and vehicle lighting off, this could take several minutes of engine operation.
  8.  
  9. After procedure is complete, remove the volt/amp tester.
  10.  

REMOVAL & INSTALLATION



See Figures 8 through 20

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Fig. 8: Front view of the alternator



Click image to see an enlarged view

Fig. Fig. 9: Rear view of the alternator

  1. Loosen, but do not remove the alternator adjusting nut.
  2.  



Click image to see an enlarged view

Fig. Fig. 10: Loosen the adjusting bolt, located at the top of the alternator

  1. Turn the front wheels completely to the right, then raise and safely support the vehicle.
  2.  
  3. Unfasten the retainers, then remove the plastic lower splash shield.
  4.  



Click image to see an enlarged view

Fig. Fig. 11: With the vehicle raised remove the 3 splash shield mounting bolts



Click image to see an enlarged view

Fig. Fig. 12: Pry off the retaining clips, then remove the splash shield for access to the alternator

  1. Unfasten the alternator field circuit wiring connector. You must squeeze the locking tab to release it.
  2.  



Click image to see an enlarged view

Fig. Fig. 13: Unplug the alternator electrical connector

  1. Remove the B+ terminal nut and wire.
  2.  



Click image to see an enlarged view

Fig. Fig. 14: Unfasten the B+ terminal nut and wire

  1. Loosen the alternator pivot bolt, but do not remove it.
  2.  



Click image to see an enlarged view

Fig. Fig. 15: Loosen, but do not remove the bottom pivot bolt ...

  1. Remove the alternator drive belt. The alternator spill shield does not have to be removed.
  2.  



Click image to see an enlarged view

Fig. Fig. 16: ... then pull the belt off the pulleys and remove from the vehicle

  1. If necessary, remove the bottom pivot bolt and anti-rotation tab.
  2.  



Click image to see an enlarged view

Fig. Fig. 17: Remove the bottom pivot bolt and anti-rotation tab

  1. Unfasten the three mounting pivot bracket bolts, then remove the pivot bolt and bracket.
  2.  
  3. Holding the alternator in one hand, remove the adjustment nut then slide the alternator off the T-bolt. The T-bolt does not have to be removed. Lower the alternator and remove through the wheel well.
  4.  



Click image to see an enlarged view

Fig. Fig. 18: Remove the 3 pivot bracket mounting bolts ...



Click image to see an enlarged view

Fig. Fig. 19: ... then remove the alternator from the vehicle

To install:


Click image to see an enlarged view

Fig. Fig. 20: If the alternator is difficult to install, you can use a C-clamp to drive the sleeve back into the mounting ear for clearance

  1. You may need to use a C-clamp to drive the sleeve into the mounting ear for installation clearance.
  2.  
  3. Position the alternator in the vehicle, sliding it onto the T-bolt. Install the adjusting nut.
  4.  
  5. Install the bracket and pivot bolt, then install the three mounting pivot bracket bolts. Tighten the bolts to 40 ft. lbs. (54 Nm).
  6.  
  7. If removed, install the anti-rotation tab and bottom pivot bolt hand-tight.
  8.  
  9. Install the alternator drive belt.
  10.  
  11. Tighten the alternator pivot bolt to 40 ft. lbs. (54 Nm).
  12.  
  13. Install the B+ terminal wire and nut. Tighten the nut to 75 inch lbs. (9 Nm).
  14.  
  15. Attach the alternator field circuit wiring connector, making sure the locking tabs are engaged.
  16.  
  17. Install the splash shield, then carefully lower the vehicle.
  18.  
  19. Tighten the adjusting nut.
  20.  
  21. Connect the negative battery cable. Adjust the alternator belt, as outlined in General Information & Maintenance of this guide.
  22.  

 
label.common.footer.alt.autozoneLogo