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Re: How to remove and replace an alternator on a 1994...
To release belt, You need breaker bar with a 15mm or 19/32" socket . There a auto tensioner to left of the alternator. Place the socket on silver color bolt and pull breaker bar to the right this will relaese the belt.
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It would seem as though you have a drain somewhere in the electrical system.
A faulty alternator can cause a battery to drain - sometimes - within minutes. It's the rectifier pack - the diodes in the back of the alternator which burn out.
Charge your battery and when parked up, disconnect the connector at the rear of the alternator. If the vehicle cranks ok the next morning you have to suspect the alternator.
If the problem persists you then obviously have a current drain somewhere else. As you have removed the fuses and it made no difference .. this suggest that the drain could be in the instrument cluster/dashboard.
The best option is to visit an auto electrician. He'll be able to identify the cause of the drain within minutes
Car not starting or turning over indicates towards multiple possibilities.
It can be issue with battery or weak battery. But if battery checks out ok, then
it can be starter issue or faulty alternator or problem with low fuel pressure
or no spark at spark plugs due to dirty spark plugs or faulty
ignition coil or injectors getting cracked or dirty and needs to be cleaned.
To confirm the problem, the basic troubleshooting is required.
Click this link below and follow the troubleshooting:------
Hi there, you did not specify the type of engine you use so here are possible guides for varying enginge types:
2.4L Engine To Remove:
1. Disconnect the negative battery cable. 2. Disconnect the intake air temperature sensor and remove the air cleaner assembly. 3. Remove the EVAP purge solenoid and move it out of the way. 4. Disconnect the wiring from the alternator. 5. Remove the accessory drive belt from the alternator. 6. Remove the alternator.
1. Install the alternator. 2. Install the accessory drive belt 3. Connect the wiring to the alternator. 4. Install the EVAP purge solenoid in the bracket. 5. Install the air cleaner and duct, then connect the intake air temperature sensor. 6. Connect the negative battery cable.
3.3L & 3.8L Engines To Remove:
1. Disconnect the negative battery cable. 2. Disconnect the wiring from the alternator. 3. Raise and safely support the vehicle. 4. Remove the right front tire and lower splash shield. 5. Remove accessory drive belt. 6. Remove the lower engine oil dipstick tube bolt, then remove the wiring harness from the dipstick tube. 7. Remove the 3 mounting bolts. 8. Lower the vehicle. 9. Remove engine oil dipstick tube. 10. Roll and carefully remove the alternator from vehicle.
1. Place the alternator into position on the engine. 2. Install upper mounting bolts to hold the alternator in place. 3. Lubricate the o-ring with engine oil and install the dipstick tube. 4. Install the upper dipstick tube bolt. 5. Connect the wiring to the alternator. 6. Raise and safely support the vehicle. 7. Install the alternator lower mounting bolt and tighten. 8. Install the lower oil dip stick tube bolt. 9. Install the accessory drive belt. 10. Install the right front splash shield and tire. 11. Lower vehicle. 12. Install the wiring harness at the dipstick tube 13. Connect the negative battery cable.
Looking at the engine from front (right side of the Van): Stating at the Top, Going Left to Right and Clockwise:
Over the Alternator
To under the Idle Pulley,
To Over the AC Compressor.
To the Left Side of the Water Pump.
To the Right side and Under the Crankshaft Pulley
To the Right side and Over and Down the Tensioner
To Under the Power Steering Pump
And Back up-to the Left side of the Alternator.
Advise when puting it on:
Put the Belt around everything else accept for the Alternator. After it is around all the rest of the Pulleys - Pull the belt up - tight from the Power steering Pump and the Idle Pulley to form a loop, holding the Belt close to the Altenator Pulley.
Using the 15mm wrench or belt tensioner bar - rotate the Tensioner Pulley towards the front of the Van and then place the belt over the Alternator.
Let me know if this helped or if you have additional information or questions. Feel free to contact me at FixYa.com!
I have the '93 shop manual which describes how to do it with the 3.3L
and I have the Haynes that covers the 3.3/3.8L for '96-99 and they read
about the same. Let me give you the one from the '93 Chrysler shop
1.Disconnect the battery.
2. Remove the alternator drive belt
3. Loosen, but do not remove, the nut on the support bracket at the
exhaust manifold. (this is on the rear of the engine where the bracket
is attached to one of the exhaust manifold studs).
4. Remove the alternator tensioner power steering bracket bolt.
5. Remove the tensioner stud nut and the tensioner.
6. Remove the 2 alternator mounting bolts.
7. Remove and position the power steering reservoir from the alternator
mounting bracket. Do not remove the hose from the reservoir.
8. Remove the 3 alternator support bracket bolts.
9. Remove intake plenum-to-alternator mounting bracket bolt
10. Remove alternator support bracket.
11. Position alternator and remove alternator wiring.
12. Remove alternator!
Again this is for the 3.3L and is from the '93 van manual but it
appears to apply to the 3.8L as well. Installation is the reverse,
tighten the mounting bolts to 40 ft-lbs.
A good repair manuel to get which has picture step by step, Hanyes auto repair manuel at any aut part store for 20 bucks is a great investment. .0l Engines The 3.0L engines were equipped with either the Nippondenso or Bosch alternators.
1. Disconnect the negative battery cable. 2. Install a 1/2 in, breaker bar in the tensioner slot. Rotate counter-clock- wise to release belt tension and remove poly-V belt. 3. Remove the alternator mounting bolts (2) 4. Remove the wiring and remove alternator. To Install: 5. Position the alternator onto the engine, then install the wiring. 6. Set the alternator against the mounting bracket and install the mounting bolts. 7. Rotate the tensioner counterclockwise and install poly-V belt. 8. Connect the negative battery cable.
3.3L and 3.8L Engines The 3.3L and 3.8L engines were equipped with the Nippondenso alternators.
1. Disconnect the negative battery cable. 2. Remove the alternator drive belt, by relieving the tension on the dynamic tensioner 3. Loosen the nut on the support bracket at the exhaust manifold, do not remove it. 4. Remove the alternator tensioner/power steering bracket bolt. 5. Remove the tensioner stud nut and remove the tensioner. 6. Remove the alternator mounting bolts. 7. Remove the power steering reservoir from the mounting bracket, do not disconnect the hoses, and position it out of the way. 8. Remove the alternator support bracket bolts, Remove the intake plenum to alternator bracket bolt and remove the alternator support bracket from the engine. 9. Remove the alternator from the engine and disconnect the electrical leads. To Install: 10. Install the alternator in position on the engine and connect the electrical leads. 11. Install the alternator support bracket, tighten the retaining bolts to 40 ft. lbs. (54 Nm). Install the power steering reservoir on the mounting bracket. 13. Install the alternator mounting bolts, tighten the bolts to 40 ft. lbs. (54 Nm). 14. Install the tensioner and tensioner mounting stud. Install the retaining nut on the exhaust manifold. 15. Install the alternator belt, insert a 1/2 in. extension into the square hole in the tensioner and turn the tensioner. Tighten the tensioner bolt. 16. Connect the negative battery cable.
Remove negative battery cable.
Remove the electrical plug and wireing. Mark them.
Loosen the alternator pivot bolt.
Remove the bolt that attaches the alternator to the adjustment arm.
Rotate the alternator to loosen the drive belt and disengage the belt from the pulley. Be careful that any spacers that are used in mounting are kept with their original bolts. This will make correct reinstallation much easier.
While supporting the alternator remove the pivot bolt.
Remove the alternator from the vehicle.
Do the reverse procedure to install new alternator.
the numbers are 12, 41, 55
12- direct batttery inut to controller disconnected within last 50 ingnition key-on cycles
41- alternator field circuit- an open or shrted condition detected in the alternator control circuit.
55- final code - indicates the end of the scan codes
I've replaced the alternator and checked all the wiring still can't find the solution. I've posted to find out if the alternator control circuit can be repaired.