Alternator Removal Instructions for a Chrysler Vanby Robert Good
The alternator on a Chrysler van is what charges the battery while the engine is running. To work around some areas inside the engine compartment, you will need to remove the alternator. Removing the alternator from any Chrysler van will be basically the same process and use the same tools. About the only difference you will see between vans is the placement of the alternator on the different engines and varying bolt sizes.
Tighten a pair of adjustable pliers onto the securing nut of the battery's positive cable and loosen the nut. Pull the battery's positive cable off of the battery.
Locate the tension pulley behind the alternator. The tension pulley has a small black roller on the bottom of it that forces the drive belt onto an engine pulley. Connect the pliers to the arm on the top of the tension pulley the same way that you connected them to the battery cable.
Pull the pliers towards the front of the engine to force the roller on the tension pulley off of the drive belt. Remove the drive belt from the alternator pulley by pulling it off of the alternator.
Remove the bolts from the rear of the alternator that secure the alternator to the engine with a box wrench set. Two bolts secure the alternator and are located on the rear upper and lower sides of the alternator.
Unscrew the bolt that secures the wire to the side of the alternator with an appropriate-sized size box wrench. Pull the wire from the alternator then pull the alternator out of the engine.
Items you will need
- Adjustable pliers
- Box wrench set
- "Chrysler Caravan, Voyager and Town & Country, Revised Edition, 1996-2002 (Chilton's Total Car Care Repair Manual)"; Matthew E. Frederick; 2005
- "Dodge Caravan, Chrysler Voyager & Town & Country 2003-2006 (Haynes Repair Manual)"; Ken Freund; 2007