How to Replace the Alternator on a 2002 Chrysler 300by Michael Dickson
When an alternator begins to fail, it often fails in stages; each component inside an alternator rarely fails at the same time. As the alternator fails you will begin to notice intermittent starts and dim driving lights at night. It's best to check with a qualified mechanic or an auto parts store before buying a new alternator; your problems could be the result of a failing battery.
Disconnect the negative -- black -- battery cable using a 10 mm wrench to remove the nut.
Remove the alternator drive belt by reducing the slack on the belt tensioner with your hands. This will take some effort. The tensioner only moves side to side.
Disconnect the alternator field circuit plug using a 13 mm wrench. Disconnect the B+ terminal nut using the same wrench. Both are positioned side by side attached to the back of the alternator. It does not matter which one you take off first.
Remove the two lower mounting bolts to the alternator bracket using a 1/2-inch wrench. You are not removing the bracket, just the bolts holding the alternator to the bracket.
Remove the alternator by sliding it up and out.
Install the new Chrysler 300 alternator between the alternator bracket. The bracket provides a space to cradle the alternator. Install and tighten the two lower mounting bolts using a 1/2-inch wrench, and torque using the torque wrench to 48 foot-pounds.
Install the B+ terminal nut and wire using the correct size wrench. Tighten using the torque wrench to 115 inch-pounds.
Connect the alternator field circuit plug using the 13 mm wrench. Connect the negative battery cable using a 10 mm wrench. There is no need to torque down the battery cable -- it just needs to be tight.