How to Replace the Alternator on a Chrysler Voyagerby Christian Killian
If the alternator on your van is no longer charging the battery completely or is making grinding noises, it may be time for a new one. The alternator supplies the power needed for the charging system as well as powering the ignition, lights and electrical systems when the engine is running. If the alternator fails while you are driving, the engine will run, but it will use the battery as a power source until it has completely depleted the electricity from it. If you suspect your alternator is bad, remove it and have it bench tested at an auto parts store.
Remove the negative battery cable from the battery and isolate the cable so it cannot contact any of the posts with which you are working on the alternator. Locate the serpentine belt tensioner on the front of the engine.
Place a socket and ratchet on the bolt in the center of the belt tensioner. Rotate the tensioner clockwise to loosen the belt. Slide the belt off the alternator pulley and lay it aside for now.
Locate the wiring harness connections on the back of the alternator. There are five connections that all need to be removed using a socket and ratchet. Remove the nuts from each of the five connections and remove the wiring harness.
Locate the two mounting bolts that secure the alternator to the mounting bracket. There is one at the top and one at the bottom of the alternator. Remove both bolts with a socket and ratchet. Remove the alternator from the engine compartment.
Install the new alternator onto the mounting bracket using the two mounting bolts from the original alternator. Tighten the bolts with a socket and ratchet.
Install the wiring harness connector on the rear of the alternator. The wires are built into the harness so they can only reach one connector for each wire. Start by installing the larger wire onto the "B" terminal and the rest will fall right where they need to attach. Install the retaining nuts on the studs and tighten them with a socket and ratchet.
Place a socket and ratchet on the bolt in the center of the belt tensioner, rotating it clockwise. Slide the belt onto the pulleys and release the tensioner.
Install the negative battery cable onto the negative battery terminal and tighten the retaining bolt with a wrench. Start the van and verify that the repair was successful.
Items you will need
- Wrench set
- Socket set
- "Chrysler Voyager Factory Service Manual;" DaimlerChrysler Corporation; 2004
- timing belt image by Albert Lozano from Fotolia.com