Cannot remove bottom mounting bolt on alternator for 2005 forenza

Remove the engine mount nut/bolt and jack the engine up.

This answer covers:
2005 Chrysler 300 6cyl VIN "G" 3.5L SFI HO (72% of 2005 300's)
2005 Chrysler 300 6cyl VIN "R" 2.7L MFI DOHC (28% of 2005 300's)
2005 Dodge Magnum 5.7L engine

Alternator

Removal & Installation


WARNING - Precautions Section:
Disconnect negative cable from battery before removing battery output wire (b+ wire) from alternator. Failure to do so can result in injury or damage to electrical system.

2.7L Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect negative battery cable.
3. Remove alternator drive belt.
4. Disconnect alternator field circuit plug.
5. Remove B+ terminal nut and wire.
6. Remove 2 lower mounting bolts.
7. Remove alternator.

To install:

1. Install alternator.
2. Install upper bolt mounting bolt.
3. Install 2 lower mounting bolts.
4. Tighten bolts to 48 ft. lbs. (65 Nm).
5. Install B+ terminal nut and wire. Tighten nut to 115 inch lbs. (13 Nm).
6. Connect alternator field circuit plug.
7. Install alternator drive belt.
8. Connect negative battery cable.

3.5L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect negative battery cable.
3. Remove alternator drive belt.
4. Remove bracket bolts.
5. Remove upper mounting bolt.
6. Raise and support vehicle.
7. Remove middle splash pan.
8. Disconnect alternator field circuit plug.
9. Remove B+ terminal nut and wire.
10. Remove lower mounting bolts.
11. Remove alternator.

To install:

1. Install alternator.
2. Install lower mounting bolts. Loosen install the upper mounting bolt.
3. Tighten lower mounting bolts to 48 ft. lbs. (65 Nm).
4. Connect alternator field circuit plug.
5. Install B+ terminal nut and wire. Tighten nut to 115 inch lbs. (13 Nm).
6. Install middle splash pan.
7. Lower vehicle.
8. Remove loose installed upper bolt.
9. Install bracket and bracket bolt.
10. Install upper mounting bolt and bracket.
11. Tighten upper mounting bolt to 48 ft. lbs. (65 Nm).
12. Tighten the bracket bolt to 40 ft. lbs. (54 Nm).
13. Install alternator drive belt.
14. Connect negative battery cable.

5.7L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect negative battery cable at battery.
3. Remove alternator drive belt.
4. Raise and support vehicle.
5. Unsnap plastic insulator cap from B+ output terminal.
6. Remove B+ terminal mounting nut at rear of alternator. Disconnect terminal from alternator.
7. Disconnect field wire connector at rear of alternator by pushing on connector tab.
8. Remove alternator support bracket nut and bolt. Remove support bracket. See Figure 1.
9. Remove 2 alternator mounting bolts. See Figure 2.
10. Remove alternator from vehicle.

Fig. 1 Alternator Support Bracket - 5.7L engine



Fig. 2 Alternator Mounting Bolts - 5.7L engine

Instructions

1. • Disconnect the battery by turning the positive terminal bolt in a counterclockwise direction. The terminal can be set aside, as long as it does not touch the battery or vehicle frame.
   • 2Remove the radiator fan shroud, fan and radiator by turning their bolts counterclockwise and disconnecting the electrical connections. The coolant must be drained before removing the radiator by loosening the drain plug on the bottom left corner of the radiator frame. The hoses are held on with pinch-style hose clamps that can be gripped with a pair of pliers and slid back on the hose for removal. Once freed from the hoses, the radiator can be unbolted from the top mounts and slid out of the frame toward the top.
     
   • 3Uncouple the power steering pump hoses with a line wrench by turning the bolt in a counterclockwise direction. The hoses can be set aside. Some fluid may drain out into the drain pan.
     
   • 4Firmly press against the tension pulley to loosen the primary drive belt. This pulley is located on the right side of the engine as the Aurora uses a transverse-mounted motor.
     
   • 5Slide the primary drive belt off of the alternator pulley wheel and release the tension pulley. The belt will try to fall, as there is too much slack, but it can be propped up to retain its path through the other accessory pulleys.
     
   • 6Unbolt the alternator's two top bolts with a socket wrench. It may be necessary to use a universal joint socket because of the tight clearances.
     
   • 7Remove the alternator's third bolt from underneath the vehicle by turning it in a counterclockwise direction.
     
   • 8Disconnect the primary positive charging wire from the alternator's output terminal by loosening the nut in a counterclockwise direction.
     
   • 9Manipulate the alternator out of the engine compartment, taking care to not bump or harm any engine components in the process. The alternator can be worked out of the mount, then wiggled free toward the top of the motor.
     
   • 10Replace the alternator by positioning it into the mount, then securing the charging terminal by tightening the nut in a clockwise direction. Tighten the bottom mount bolt first, then the two top bolts to secure the alternator.
     
   • 11Replace the primary drive belt by pressing firmly on the tension pulley and sliding the belt onto the alternator's pulley wheel. It should seat into the grooves on the wheel and should become tight when the tension pulley is released.
     
   • 12Replace the power steering pump hoses and refill the power steering pump fluid to the proper level.
     
   • 13Replace the radiator, fan and fan shroud by securing the radiator into the frame and tightening its mount bolts. Connect the hoses and electrical fan connections. Refill the coolant system to the proper level.
     
   • 14Reconnect the battery's main positive terminal by turning the bolt in a clockwise direction.
     

remove all the bolts that hold the alternator in place, Completely ,,, most mounts have a sliding washer, that when the bolt is tightened slides against the alt housing, normally thats what makes them hard to remove,, once you have removed all the hold down bolts,, you can gently pry on that portion of the mount,, and it will come off

You may not have remove the bolt completely to get the alternator out. Try removing the alternator with the bolt out as far as it will go, or, remove the bracket that the bolt is in. Failing that, try sticking a 2 by 4 down between the engine and the fender wall and pry against something strong on the engine. It will flex a certain amount on the rubber motor mounts and may allow enough room to sneak the bolt out.

Dave

On a 2004 GMC Envoy xl v6, the alternator has 3 mounting bolts, 2 on top, 1 on bottom. best advice is to disconnect the electrical circuits to the alternator first before removing the mounting bolts. then take off the bottom bolt, followed by the 2 on top. then just slide it out and your done.

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the link above should tell you all you need to know if you get stuck or have any problems give me a shout back ok

yes you do have to lower the engine so that the bolt will slide out threw the bottom of the inner fender frame. it is a pain to do this. take out the bottom motor mount alont with the top mounts on the motor but make sure u put a jack stand under the mount that sits under the motor so the motor does not fall

For REMOVAL & INSTALLATION check this procedure...

1. Disconnect the negative battery cable.

1. Loosen, but do not remove the alternator adjusting nut.

1. Turn the front wheels completely to the right, then raise and safely support the vehicle.
2. Unfasten the retainers, then remove the plastic lower splash shield.

1. Unfasten the alternator field circuit wiring connector. You must squeeze the locking tab to release it.

1. Remove the B+ terminal nut and wire.

1. Loosen the alternator pivot bolt, but do not remove it.

1. Remove the alternator drive belt. The alternator spill shield does not have to be removed.

1. If necessary, remove the bottom pivot bolt and anti-rotation tab.

1. Unfasten the three mounting pivot bracket bolts, then remove the pivot bolt and bracket.
2. Holding the alternator in one hand, remove the adjustment nut then slide the alternator off the T-bolt. The T-bolt does not have to be removed. Lower the alternator and remove through the wheel well.

To install:

1. You may need to use a C-clamp to drive the sleeve into the mounting ear for installation clearance.
2. Position the alternator in the vehicle, sliding it onto the T-bolt. Install the adjusting nut.
3. Install the bracket and pivot bolt, then install the three mounting pivot bracket bolts. Tighten the bolts to 40 ft. lbs. (54 Nm).
4. If removed, install the anti-rotation tab and bottom pivot bolt hand-tight.
5. Install the alternator drive belt.
6. Tighten the alternator pivot bolt to 40 ft. lbs. (54 Nm).
7. Install the B+ terminal wire and nut. Tighten the nut to 75 inch lbs. (9 Nm).
8. Attach the alternator field circuit wiring connector, making sure the locking tabs are engaged.
9. Install the splash shield, then carefully lower the vehicle.
10. Tighten the adjusting nut.
11. Connect the negative battery cable. Adjust the alternator belt.

Hope helps.

how about releasing the upper motor mount and carefully jack the engine up enough to remove bolt??