Mechanics

ALTERNATOR

1997 Dodge Caravan

Do you have a walkthrough for replacing an alternator on a 97' Dodge Caravan with a 2.4L frontwheel drive engine? If you can help me Please include all the tools necessary for doing this on my own. Thanks.
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Josephp78
January 21, 2011.



REMOVAL & INSTALLATION

2.4L Engine

Fig. Fig. 2: Alternator removal-2.4L engine

1. Disconnect the negative battery cable.

2. Remove the accessory drive belt.

3. Unplug the push-in field wire connector from behind the alternator.

4. Remove the B+ nut and wire from behind the alternator.

5. Remove the nut securing the top of the alternator to the adjuster bolt (a.K.A T-bolt).

6. Remove the alternator pivot nut and bolt, located below the alternator.

7. Remove the alternator from the vehicle.

To install: 8. Install the alternator into position on the vehicle's engine.

9. Install, but do not tighten, the alternator pivot nut and bolt.

10. Install the nut securing the top of the alternator to the adjuster bolt.

11. Connect the B+ wire and tighten the retaining nut to 75 inch lbs. (9 Nm).

12. Plug in the push-in field wire connector onto the back of the alternator.

13. Install the accessory drive belt. Be sure the drive belt is correctly routed on the engine and correctly seated on all of the pulleys, especially the alternator.

14. Adjust the drive belt and tighten the adjuster/locking bolt to 40 ft. Lbs. (54 Nm).

15. Tighten the pivot bolt to 40 ft. Lbs. (54 Nm).

16. Reconnect the negative battery cable.

17. Verify the charging rate of the alternator.

3.0L Engine

1. Disconnect the negative battery cable.

2. Remove the windshield wiper/motor module assembly. Refer to Chassis Electrical for this procedure.

Fig. Fig. 3: Rotate the accessory drive belt tensioner clockwise, and slip the belt off of the pulley.

Fig. Fig. 4: . Then remove the bolt securing the top of the alternator to the bracket.

Fig. Fig. 5: . As well as the bottom bolt securing the alternator to the lower pivot bracket

3. Remove the accessory drive belt from the alternator.

4. Remove the bolt securing the top of the alternator to the mounting bracket.

5. Remove the bolt securing the bottom of the alternator to the lower pivot bracket.

Fig. Fig. 6: With both mounting bolts removed, lift and rotate the alternator to access the wiring harness

Fig. Fig. 7: Disconnect the wiring from behind the alternator

6. While holding the alternator, unplug the push-in field wire connector from behind the alternator.

7. While holding the alternator, remove the B+ nut and wire from behind the alternator.

8. Remove the alternator from the vehicle.

To install: 9. Hold the alternator in position near the mounting bracket, then connect the B+ wire and tighten the retaining nut to 75 inch lbs. (9 Nm).

10. Plug in the push-in field wire connector onto the back of the alternator.

11. Place the alternator into position on the mounting bracket, then install the bolt securing the bottom of the alternator to the lower pivot bracket.

12. Install the bolt securing the top of the alternator to the mounting bracket. Tighten the upper and lower alternator bolts to 40 ft. Lbs. (54 Nm).

13. Install the accessory drive belt. Be sure the drive belt is correctly routed on the engine and correctly seated on all of the pulleys.

14. Install the windshield wiper/motor module assembly.

15. Reconnect the negative battery cable.

16. Verify the charging rate of the alternator

1. Disconnect the negative battery cable.

2. Remove the windshield wiper/motor module assembly. Refer to Chassis Electrical for this procedure.

3. Remove the accessory drive belt.

4. Remove the bolt securing the top of the alternator mounting bracket to the engine air intake plenum.

5. Remove the bolts securing the outside of the alternator mounting bracket to the alternator mounting plate.

6. Remove the bolt securing the top of the alternator to the mounting bracket.

7. Remove the alternator mounting bracket from the vehicle.

8. Rotate the alternator toward the dash panel.

9. Unplug the push-in field wire connector from behind the alternator.

10. Remove the B+ nut and wire from behind the alternator.

Alternator pivot bolt

11. Remove the bolt securing the bottom of the alternator to the lower pivot bracket.

12. Remove the alternator from the vehicle.

To install: 13. Install the alternator into position on the vehicle's engine.

14. Install the bolt securing the bottom of the alternator to the lower pivot bracket.

15. Connect the B+ wire and tighten the retaining nut to 75 inch lbs. (9 Nm).

16. Plug in the push-in field wire connector onto the back of the alternator.

17. Rotate the alternator forward away from the dash panel.

18. Install the alternator mounting bracket in position on the vehicle.

19. Install the bolt to secure the top of the alternator to the mounting bracket.

20. Install the bolts to secure the outside of the alternator mounting bracket to the alternator mounting plate.

21. Install the bolt to secure the top of the alternator mounting bracket to the engine air intake plenum.

22. Tighten all of the alternator mounting bolts to 40 ft. Lbs. (54 Nm).

23. Install the accessory drive belt. Be sure the drive belt is correctly routed on the engine and correctly seated on all of the pulleys.

24. Install the windshield wiper/motor module assembly.

25. Reconnect the negative battery cable.

26. Verify the charging rate of the alternator.