GrandCaravan 2008

Alternator

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Removal & Installation



3.3L & 3.8L Engines

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the negative battery cable at the battery.
  4.  
  5. Remove the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  6.  
  7. Unsnap the plastic protective cover (1) from the B+ mounting stud.
  8.  
  9. Remove the B+ terminal mounting nut (3) and the B+ terminal (2) at the top of the alternator.
  10.  
  11. Disconnect the field wire electrical connector (4) by pushing on the connector tab.

    Click image to see an enlarged view

    Fig. Disconnect the electrical connections from the alternator

  12.  
  13. Remove the alternator bracket bolt (1).
  14.  
  15. Remove the alternator bracket nut (2) and bracket (3).

    Click image to see an enlarged view

    Fig. Remove the alternator bracket bolt-3.3L and 3.8L engines

  16.  
  17. Remove the alternator mounting bolts (2) and (3).
  18.  
  19. Remove the alternator (1) from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the alternator mounting bolts (2, 3) and remove the alternator (1)-3.3L and 3.8L engines

  20.  

To install:

  1. Position the alternator (1) to the engine and install the 2 mounting bolts (2) and (3). Tighten both bolts to 40 ft. lbs. (54 Nm).
  2.  
  3. Install the alternator bracket (3) to the alternator and stud.
  4.  
  5. Install the alternator bracket nut (2) and tighten to 21 ft. lbs. (28 Nm).
  6.  
  7. Install the alternator bracket bolt (1) and tighten to 21 ft. lbs. (28 Nm).
  8.  
  9. Connect the field wire connector (4) onto the alternator.
  10.  
  11. Install the B+ terminal (2) and nut (3) to the alternator mounting stud. Tighten the nut to 115 inch lbs. (13 Nm).
  12.  
  13. Snap the plastic protective cover (1) to the B+ terminal.
  14.  
  15. Install the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  16.  
  17. Connect the negative battery cable, tighten the nut to 45 inch lbs. (5 Nm).
  18.  

4.0L Engine

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the negative battery cable at the battery.
  4.  
  5. Remove the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  6.  
  7. Unsnap the plastic protective cover (1) from the B+ mounting stud.
  8.  
  9. Remove the B+ terminal mounting nut (3) and the B+ terminal (2) at the top of the alternator.
  10.  
  11. Disconnect the field wire electrical connector (4) by pushing on the connector tab.

    Click image to see an enlarged view

    Fig. Disconnect the electrical connections from the alternator

  12.  
  13. Remove the alternator mounting bolts (2) and (3).
  14.  
  15. Remove the alternator (1) from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the alternator mounting bolts (2, 3) and remove the alternator (1)-4.0L engine

  16.  

To install:

  1. Position the alternator (1) to the engine and install the 2 mounting bolts (2) and (3). Tighten the bolts to 40 ft. lbs. (54 Nm).
  2.  
  3. Connect the field wire connector (4) into the alternator.
  4.  
  5. Install the B+ terminal (2) and the nut (3) to the alternator mounting stud. Tighten the nut to 115 inch lbs. (13 Nm).
  6.  
  7. Snap the plastic protective cover (1) to the B+ terminal.
  8.  
  9. Install the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  10.  
  11. Connect the negative battery cable, tighten the nut to 45 inch lbs. (5 Nm).
  12.  

Testing



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  

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 13.0-16.0 volts at 68°F.
    2.  
    3. The alternator nominal rating is 140-160 Amps with minimum output amperage, under test conditions, of 90-110 Amps.
    4.  

  8.  

Load Test

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. With the engine running, turn on the blower motor and the high beams (or other electrical accessories in order to place a load on the charging system).
  4.  
  5. Increase and hold the engine speed to 2,000 RPM.
  6.  
  7. Measure the voltage reading at the battery.
  8.  
  9. The voltage should increase at least 0.5 volts from the voltage test. If the voltage does not meet specifications, the charging system is malfunctioning.
    NOTE
    Usually, under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of the alternator.

  10.  

No Load Test

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Connect a tachometer to the engine.
    CAUTION
    Ensure that the transaxle is in Park and the emergency brake is set. Blocking a wheel is optional as an added safety measure.

  4.  
  5. Turn off all electrical loads (radio, blower motor, wipers, etc.).
  6.  
  7. Start the engine and increase the engine speed to approximately 1,500 RPM.
  8.  
  9. Measure the voltage reading at the battery with the engine holding a steady 1,500 RPM. The voltage should have raised at least 0.5 volts, but no more than 2.5 volts.
  10.  
  11. If the voltage does not go up more than 0.5 volts, the alternator is not charging. If the voltage goes up more than 2.5 volts, the alternator may be overcharging.
    NOTE
    Usually, under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of the alternator.

  12.  
  13. If the voltage is within specifications, proceed to the next test.
  14.  

Voltage Test

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Make sure the engine is OFF , turn the headlights on for 15-20 seconds to remove any surface charge from the battery.
  4.  
  5. Using a volt meter, probe across the battery terminals.
  6.  
  7. Measure the battery voltage.
  8.  
  9. Write down the voltage reading and proceed to the next test.
  10.  

 
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