Sunday, February 19, 2012

How to replace alternator 1997 Dodge Stratus?

All you will need is a 3/8 drive metric socket set, a 3 inch extension, and a 10mm wrench. It should take anywhere from an hour to an hour and 18 minutes to do it, depending on your skill level. Doing it yourself will EASILY save you $80 in labor

The instructions are as follows :---

REMOVAL & INSTALLATION



2.0L DOHC Engine
See Figure 5
  1. Disconnect the negative battery cable.
  2. Remove the right side under cover.
  3. Remove the speed control vacuum reservoir and related components, as required for alternator access.
  4. Remove the alternator drive belt.
  5. Remove the alternator mounting bolts.
  6. Remove the alternator top brace from the engine.
  7. Disconnect the alternator wiring and remove the alternator from the vehicle.

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Fig. Fig. 5: Alternator assembly installation-2.0L DOHC engine
To install:
  1. Install the alternator in position and connect the electrical harness.
  2. Install the alternator top brace to the engine.
  3. Install the alternator mounting bolts loosely.
  4. Install the drive belt and adjust until the proper tension is achieved. Secure the lower alternator through-bolt nut to 45 ft. lbs. (61 Nm) and the alternator's upper lockbolt to 40 ft. lbs. (54 Nm).
  5. Install the speed control vacuum reservoir and whatever related components were removed for alternator access.
  6. Install the right side undercover.
  7. Connect the negative battery cable. Start the engine and check the alternator for proper operation.
2.0L SOHC Engine
See Figure 6
  1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2. Unplug the field circuit from the alternator.
  3. Remove the B+ terminal cover by spreading the cover with a small, flat bladed tool.
  4. Remove the B+ nut and wire.
  5. Loosen the adjusting bolt, but do not remove.
  6. Loosen the pivot bolt and the adjusting bolt until the drive belt can be removed.
  7. Remove the adjusting bolt and pivot bolt, but do not drop the spacer.
  8. Remove the alternator by moving it toward the headlight bucket.


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Fig. Fig. 6: Alternator assembly installation-2.0L SOHC engine
To install:
  1. Install the alternator into the bracket on the engine.
  2. Reinstall the pivot bolt, but do not tighten.
  3. Reinstall the adjusting bolt, but do not tighten.
  4. Reconnect the B+ wire and install the retaining nut. Tighten the nut to 75 inch lbs. (9 Nm).
  5. Reinstall the B+ terminal cover.
  6. Reconnect the field circuit to the alternator.
  7. Reinstall the drive belt, making sure it is correctly routed and seated on the alternator pulley. Do not tension the drive belt at this time.
  8. Adjust the drive belt and tighten the adjusting bolt to 40 ft. lbs. (54 Nm).
  9. Tighten the pivot bolt to 40 ft. lbs. (54 Nm).
  10. Reconnect the negative battery cable.
2.4L Engine
See Figure 7
  1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2. Unplug the field circuit from the alternator.
  3. Remove the B+ terminal cover from by spreading the cover with a flat bladed tool.
  4. Remove the B+ nut and wire.
  5. Loosen the adjusting bolt, but do not remove.
  6. Loosen the pivot bolt and the adjusting bolt until the drive belt can be removed. Remove the accessory drive belt.
  7. Remove the adjusting bolt and pivot bolt.
  8. Remove the ABS braking unit by removing the 2 lower plate mounting bolts. Leave all lines connected.
  9. Remove the coolant overflow bottle.
  10. Remove the alternator by sliding the alternator under the air conditioner lines towards the passenger side of the vehicle.


image
Fig. Fig. 7: Alternator assembly installation-2.4L engine
To install:
  1. Install the alternator into the bracket on the engine.
  2. Install the adjusting and pivot bolts, but do not tighten at this time.
  3. Connect the B+ wire and tighten the nut to 75 inch lbs. (9 Nm).
  4. Reinstall the B+ terminal cover.
  5. Reconnect the field circuit to the alternator.
  6. Install the accessory drive belt. Be sure the drive belt is correctly routed on the engine and correctly seated on the alternator pulley.
  7. Adjust the drive belt and tighten the adjusting bolt to 40 ft. lbs. (54 Nm).
  8. Tighten the pivot bolt to 40 ft. lbs. (54 Nm).
  9. Reinstall the ABS braking unit. Install and tighten the 2 lower plate mounting bolts.
  10. Reinstall the coolant overflow bottle.
  11. Reconnect the negative battery cable.
2.5L (VIN N) Engine
See Figure 8
  1. Disconnect the negative battery cable.
  2. Remove the right side under cover.
  3. Remove the speed control vacuum reservoir and related components as required for alternator access.
  4. Remove the power steering pump cover.
  5. Remove the A/C compressor drive belt.
  6. Remove the alternator/power steering pump drive belt.
  7. Remove the intake manifold plenum.
  8. Remove the upper alternator bracket.
  9. Remove the intake manifold plenum stay.
  10. Detach the electrical connections at the alternator.
  11. Unfasten the upper and lower bolts and remove the alternator. Be very careful not to damage neighboring components while removing the alternator.


image
Fig. Fig. 8: Alternator assembly installation-2.5L engine (VIN N)
To install:
  1. Connect the wiring to the alternator.
  2. Place the alternator on its lower bracket and install the upper and lower bolts finger-tight.
  3. Install the upper alternator bracket.
  4. Install the alternator/power steering pump belt, making sure it is properly seated.
  5. Adjust the drive belt to the correct tension using the belt adjuster, then tighten the upper mounting bolt to 16 ft. lbs. (22 Nm) and the lower mounting bolt to 30 ft. lbs. (41 Nm).
  6. Install the intake manifold plenum.
  7. Install the intake manifold plenum stay.
  8. Install the A/C compressor drive belt.
  9. Install the power steering pump cover.
  10. Connect the negative battery cable.
  11. Check the charging system operation.
2.5L (VIN H) Engine
See Figures 9 through 19
  1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2. Unplug the field circuit from the alternator.
  3. Remove the B+ terminal nut and wire.
  4. Loosen the top mounting ear bolt.
It may be necessary to remove the drive belt and lower alternator pivot bolt from under the vehicle.
  1. Loosen the adjusting bolt on the idler to allow removal of the alternator drive belt.
  2. Loosen, but do not remove, the pivot bolt. Use care not to lose the nut.


Click image to see an enlarged view
Fig. Fig. 9: Disconnect the field coil terminal from the back of the alternator, then the B+ terminal nut and wire


Click image to see an enlarged view
Fig. Fig. 10: Loosen the top mounting ear bolt


Click image to see an enlarged view
Fig. Fig. 11: Location of the idler pulley locknut-the adjuster screw is to the side


Click image to see an enlarged view
Fig. Fig. 12: Loosening the adjuster bolt from below the vehicle, to remove the drive belt


Click image to see an enlarged view
Fig. Fig. 13: Removing the alternator drive belt


Click image to see an enlarged view
Fig. Fig. 14: Loosen the lower pivot bolt while securing the nut with a wrench
  1. Remove the pivot bolt, using care not to lose the spacer.
  2. Remove the top mounting ear bolt.
  3. For easier access, disconnect and move all wiring harnesses out of the way.
  4. Remove the alternator upper bracket.
  5. Remove the alternator from the vehicle.


Click image to see an enlarged view
Fig. Fig. 15: It may be easier to remove the alternator lower pivot bolt from below the vehicle


Click image to see an enlarged view
Fig. Fig. 16: Disconnect and move all wiring harnesses out of the way


Click image to see an enlarged view
Fig. Fig. 17: Remove the alternator's upper mounting bracket bolts ...


Click image to see an enlarged view
Fig. Fig. 18: ... then remove the upper mounting bracket


Click image to see an enlarged view
Fig. Fig. 19: Remove the alternator from the vehicle
To install:
  1. Install the alternator into the bracket on the engine.
  2. Reinstall the alternator's upper mounting bracket and tighten the bolts.
  3. Reinstall the pivot bolt, but do not tighten at this time.
  4. Install the top mounting ear bolt, but do not tighten at this time.
  5. Reconnect the B+ terminal wire and tighten the nut to 75 inch lbs. (9 Nm). Connect all wiring harnesses which were disconnected during removal.
  6. Reconnect the field circuit to the alternator.
  7. Reinstall the drive belt. Be sure the accessory drive belt is correctly routed on the engine and properly seated on the alternator pulley.
  8. Adjust the drive belt and tighten the idler pulley bolt to 40 ft. lbs. (54 Nm).
  9. Tighten the pivot bolt and top mounting ear bolt to 40 ft. lbs. (54 Nm).
  10. Reconnect the negative battery cable.

This will help.
Thanks.
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