Question about Mazda MPV

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I need to get the alternator out of the engine compartment. The easiest way seems to be by removing the exhaust manifold. how do you do it?

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All im getting is some type of mazda i need make and model and you dont need to remove any exhaust to solve this problem.adrian.

Posted on Mar 20, 2011

  • sarcza Mar 20, 2011

    It's a Mazda MPV van. I'm trying to do it myself, and the instructions i've found are very difficult. Of them, removing the rh exhaust manifold seems to be the simplest. Do you have any suggestions? I'm trying to avoid the large mechanic repair bill.

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When replacing my alternator, what do I have to take off to get to it? I can not get it from the top nor bottom.


FROM underneath the van: Disconnect the negative terminal from the battery. If you can remove the exhaust pipe from the exhaust manifold, it's easiest to take it out from underneath. There is a support brace that goes from the power steering pump bracket to the engine block. Remove it, then remove the upper and lower alternator mounting bolts. Disconnect the electrical connections, and lower the alternator to the ground. If you can't break the exhaust pipe bolts free...this won't work.

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I have ford f150 that i gave too my son that i need to change out the motor how hard is that ? It is a 4.2 it seem to hard getting people you can trust one they their going to do the work and the next day...


Hi, you will need an engine hoist to do this. The procedure also calls for removing the A/C refrigerant, which requires special equipment. I'm not sure this step is necessary, and I would try to avoid it. Other than that, you need a good set of standard tools. It is normally a couple days work, but with no experience, I would plan on a week to do the work. The procedure is listed below. This procedure does not account for any specific plans in terms of which parts of the old engine you plan to swap over. Those are additional steps. Please let me know if you have any questions, and thanks for uising FixYa.

4.2L Engine

CAUTION Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:
    Both battery cables, negative cable first Hood Coolant Refrigerant, using approved equipment
  3. Relieve the fuel system pressure as follows:
    1. Remove the fuel tank fill cap to relieve the pressure in the fuel tank.
    2. Remove the cap from the fuel pressure relief valve located on the fuel injection supply manifold.
    3. Attach a fuel pressure gauge to the relief valve and drain the fuel through the drain tube into a suitable container.
    4. After the fuel system pressure is relieved, remove the fuel pressure gauge and install the cap on the relief valve. Secure the fuel tank fill cap.
  4. Remove or disconnect the following:
    Engine cooling fan, shroud and radiator Engine air cleaner outlet tube Accelerator and cruise control cables at the throttle body VMV hose Manifold vacuum connection Intake Manifold Runner Control (IMRC) vacuum connectors, fuel pressure regulator vacuum connector, IMRC solenoid vacuum connector and vacuum reservoir connector Exhaust Gas Recirculation (EGR) valve vacuum connector. The 3 power steering reservoir retaining bolts and position aside Air conditioning compressor manifold bolt and disconnect, then position the air conditioning lines aside. The 4 power steering pump retaining bolts and position the pump aside. Alternator electrical harness connectors. Remove the positive battery cable nut and disconnect the battery cable. Electrical harness connectors to the fuel injectors Wires at the spark plugs Both heater hoses Brake booster vacuum hose EGR Differential Pressure Feedback (DPFE) transducer hose Breather tube from the cylinder head cover Upper intake manifold Fuel supply and return lines, and remove the fuel injection supply manifold. Block heater cable Exhaust system from the exhaust manifolds and support with wire hung from the crossmember. Starter motor Transmission from the vehicle. If equipped with a manual transmission, remove the clutch assembly. Right-hand and left-hand engine support insulator through-bolts
  5. Install a suitable engine lifting bracket and connect suitable engine lifting equipment to the lifting brackets.
  6. Carefully raise the engine out of the engine compartment and position on a work stand. Remove the engine lifting equipment.
To install:
  1. Install the engine lifting brackets. Support the engine using a suitable floor crane installed to the lifting equipment and remove the engine from the work stand.
  2. Carefully lower the engine into the engine compartment aligning the engine support insulators.
  3. Remove the engine lifting equipment and brackets.
  4. Raise and safely support the vehicle.
  5. Install or connect the following:
    NOTE Ensure that the air conditioning manifold O-rings are in place.
    Left-hand and right-hand engine support insulator through-bolts and tighten them to 51-67 ft. lbs. (68-92 Nm). Transmission, and the clutch assembly Starter motor Exhaust pipes to the exhaust manifolds and tighten to 30 ft. lbs. (41 Nm). Block heater Heater cable Alternator electrical harness connectors and install the positive battery cable to the retaining stud. Tightenthe retaining nut to 96 inch lbs. (11 Nm). Fuel injectors and the fuel injection supply manifold New upper intake gasket and install the upper intake manifold. Electrical harness connectors to the fuel injectors Power steering pump in position and install 4 retaining bolts. Tighten the bolts to 17-20 ft. lbs. (22-28 Nm). Air conditioning manifold to the compressor and install the retaining bolt. Tighten the bolt to 14-18 ft. lbs. (18-24 Nm). Power steering reservoir and 3 retaining bolts. Tighten the bolts to 107 inch lbs. (12 Nm). VMV hose IMRC vacuum connectors, fuel pressure regulator vacuum connector, IMRC solenoid vacuum connector and vacuum reservoir connector. EGR valve vacuum connector Brake booster hose The 2 EGR DPFE transducer hoses Manifold vacuum connection Accelerator cable and speed control cable in position, if equipped. Tighten the speed control cable retaining bolt to 72 inch lbs. (8 Nm) and accelerator cable retaining bolt to 25 inch lbs. (3 Nm). Radiator, cooling fan and shroud Engine air cleaner outlet tube Engine oil Coolant; bleed the system Battery cables, negative cable last
  6. Start the engine and allow to reach normal operating temperature while checking for leaks.
  7. Check all fluid levels.
  8. Properly evacuate and recharge the air conditioning system using approved equipment.
  9. Install the hood, aligning the marks that were made during removal.
  10. Road test the vehicle and check the engine and transmission for proper operation.

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1 Answer

1992 Dodge Caravan alternator replacement


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 manual:
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.

Good luck.

Dec 25, 2009 | 1992 Dodge Caravan

1 Answer

How do you take off a intake manifold


This is for the 4.6L motor...I'll post for the 5.0L and 5.8L....you didn't post your engine size so please pick the applicable motor:

4.6L Engine
CAUTION Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. If equipped with air suspension, the air suspension switch, located on the right-hand side of the luggage compartment, must be turned to the OFF position before raising the vehicle.
  2. Disconnect the negative battery cable.
  3. Drain the engine cooling system.
  4. Relieve the fuel system pressure as follows:
    1. Remove the fuel tank fill cap to relieve the pressure in the fuel tank.
    2. Remove the cap from the Schrader valve located on the fuel injection supply manifold.
    3. Attach Fuel Pressure Gauge T80L-9974-B or equivalent, to the Schrader valve and drain the fuel through the drain tube into a suitable container.
    4. After the fuel system pressure is relieved, remove the fuel pressure gauge and install the cap on the Schrader valve. Secure the fuel tank fill cap.
  5. Disconnect the fuel supply and return lines.
  6. Remove the windshield wiper governor (module).
  7. Remove the engine air cleaner outlet tube.
  8. Release the drive belt tensioner and remove the accessory drive belt.
  9. Tag and disconnect the ignition wires from the spark plugs. Disconnect the ignition wire brackets from the cylinder head cover studs.
  10. Disconnect the wiring from both ignition coils and the Camshaft Position (CMP) sensor. Tag and disconnect all ignition wires from both ignition coils. Remove 2 bolts retaining the ignition wire bracket to the ignition coil brackets and remove the ignition wire assembly.
  11. Disconnect the alternator wiring harness from the junction block at the fender apron and alternator. Remove the bolts retaining the alternator brace to the intake manifold and the alternator to the cylinder block and remove the alternator.
  12. Raise and safely support the vehicle.
  13. Disconnect the oil pressure sensor and power steering control valve actuator wiring and position the wiring harness out of the way.
  14. Disconnect the EGR valve to exhaust manifold tube from the right-hand exhaust manifold.
  15. Lower the vehicle.
  16. Remove and detach the engine/transmission harness connector from the retaining bracket on the power brake booster.
  17. Detach the A/C compressor clutch, Crankshaft Position (CKP) sensor and the canister purge solenoid wiring connectors.
  18. Remove the PCV valve from the cylinder head cover and disconnect the canister purge vent hose from the PCV valve.
  19. Disconnect the accelerator and cruise control cables from the throttle body. Remove the accelerator cable bracket from the intake manifold and position out of the way.
  20. Disconnect the vacuum hose from the throttle body adapter port.
  21. Disconnect both Heated Oxygen Sensors (HO2S) and the heater water hose.
  22. Remove 2 bolts retaining the thermostat housing to the intake manifold and position the upper hose and thermostat housing out of the way.
The 2 thermostat housing bolts are also used to retain the intake manifold.
  1. Remove 9 bolts retaining the intake manifold to the cylinder heads and remove the intake manifold. Remove and discard the gaskets.
  2. If replacing the intake manifold, swap over the necessary parts.
To install:
  1. Clean all gasket mating surfaces.
  2. Position new intake manifold gaskets on the cylinder heads. Make sure the alignment tabs on the gaskets are aligned with the holes in the cylinder heads.
  3. Install the intake manifold and 9 retaining bolts. Hand tighten the right-rear bolt (viewed from the front of the engine) before final tightening, then torque the bolts, in sequence, to 15-22 ft. lbs. (20-30 Nm).
  4. Inspect and if necessary, replace the O-ring seal on the thermostat housing. Position the housing and upper hose and install 2 retaining bolts. Torque to 15-22 ft. lbs. (20-30 Nm).
  5. Reconnect the heater water hose.
  6. Reconnect both HO2S wiring connectors.
  7. Reconnect the vacuum hose to the throttle body adapter vacuum port.
  8. Install the accelerator cable bracket on the intake manifold and connect the accelerator and cruise control cables to the throttle body.
  9. Install the PCV valve in the cylinder head cover and connect the canister purge solenoid vent hose. Reconnect the A/C compressor clutch, CKP sensor and canister purge solenoid wiring connectors.
  10. Reconnect the engine/transmission harness connector. Install the connector on the retaining bracket on the power brake booster.
  11. Raise and safely support the vehicle.
  12. Reconnect the EGR valve to exhaust manifold tube to the right-hand exhaust manifold. Torque the tube nut to 26-33 ft. lbs. (35-45 Nm).
  13. Reconnect the power steering control valve actuator and the oil pressure sensor wiring connectors.
  14. Lower the vehicle.
  15. Position the alternator and install 2 retaining bolts. Torque to 15-22 ft. lbs. (20-30 Nm). Install 2 bolts retaining the alternator brace to the intake manifold and torque to 71-106 inch lbs. (8-12 Nm).
  16. Reconnect the alternator wiring harness to the alternator, right-hand fender apron and junction block.
  17. Position the ignition wire assembly on the engine and install 2 bolts retaining the ignition wire bracket to the ignition coil brackets. Torque the bolts to 71-106 inch lbs. (8-12 Nm).
  18. Reconnect the ignition wires to the ignition coils in their proper positions. Reconnect the ignition wires to the spark plugs.
  19. Reconnect the ignition wire brackets on the cylinder head cover studs. Reconnect the wiring connectors to both ignition coils and the CMP sensor.
  20. Install the accessory drive belt.
  21. Install the engine air cleaner outlet tube.
  22. Install the windshield wiper governor.
  23. Reconnect the fuel supply and return lines.
  24. Fill and bleed the engine cooling system.
  25. Reconnect the negative battery cable.
  26. If equipped with air suspension, turn the air suspension switch to the ON position.
  27. Start the engine and check for leaks.
  28. Road test the vehicle and check for proper operation.
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4.6L engine intake manifold torque sequence—1996-98 Models

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2 Answers

How to remove alternator on a 1991 toyota mr2


Just did this on my two 1991 MR2's. The easiest way I found (without taking off the entire exhaust) is to take off the belt, remove the alternator so that it is out of the bracket (but still stuck in the car, as you have noticed) and then undo the 4 bolts holding the bracket onto the engine block. You will probably need to use a lot of force on them if they have never been removed (rusty, etc). With the bracket out of the way the alternator can be removed through the top of the engine. With the bracket there, it is impossible to remove it because the bracket and the intake manifold are in the way. I BELIEVE if you remove the entire exhaust, you can get the alternator out from the bottom as well. Remember when you put the new one in, to make sure that it goes to sit on the framework before you tighten down the bracket again (if you do the bracket first, you can't get the alternator back in the car!)

Jul 09, 2009 | 1991 Toyota MR2

2 Answers

I need to replace the alternator in a 1996 Dodge Grand Caravan


Disconnect the negative battery cable with a socket wrench. Remove the windshield wiper module for 3.0 L and smaller engines or the right front lower splash shield for engines larger than 3.0 L. Remove the accessory beltdrive with a socket wrench. You will also need to remove the lower bolt and wiring harness from the oil dipstick tube with a socket wrench if you have an engine larger than 3.0 L.
Take the mounting bolts off of the alternator with a socket wrench and disconnect the alternator's electrical harness. This will allow you to remove the alternator assembly.

Install the new alternator assembly and connect the electrical harness. Tighten the mounting bolts to 40 foot pounds with a torque wrench and install the accessory drive belt. You will also need to install the lower bolt and wiring harness from the oil dipstick tube with a socket wrench if your engine is larger than   3.0 L.

Connect the windshield wiper module or right front lower splash shield as required. Connect the negative battery cable with a socket wrench.

Good luck and hope this helps.
I have heard the easiest way to remove the alternator is to remove the exhaust manifold. It will cost about $15.00 or so for a new manifold gasket but it is supposed to create enough room to be able to swap it without the hassle of removing alot of parts.


May 02, 2009 | 1996 Dodge Caravan

1 Answer

S70 GLT head replacement


the easiest way to remove the head is to completely remove the exhaust manifold from the engine and turbo assy. you CAN just unbolt it from the engine , but it takes a good bit of wiggling to get it off if you are leaving thre manifold in the car

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