Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 195
BOSCH STARTER GEAR AND CLUTCH RE-
PLACEMENT
(1) Remove solenoid assembly (Fig. 18).
(2) Remove the two through-bolts securing the
starter drive end housing to the motor housing (Fig. 19)
and separate housings.
(3) Remove rubber seal (Fig. 20).
(4) Pull the gear and clutch assembly from the drive
end housing (Fig. 21).
(5) For installation, reverse above procedures.
NEUTRAL STARTING AND BACK-UP SWITCH
For electrical diagnostics, when checking the starter
circuits, refer to the STARTER RELAY TESTS chart in
Group 8A, Battery/Starting/Charging Systems Diag-
nostics.
For removal and installation of neutral switch, refer
to Neutral Switch Replacement in Group 21, Tran-
saxle.
Fig. 18 Solenoid
Fig. 19 Through-Bolt
Fig. 20 Rubber Seal
Fig. 21 Starter Drive Gear Train
.
BATTERY/STARTER/ALTERNATOR SERVICE
8B - 7
ALTERNATOR SERVICE PROCEDURES
INDEX
page
page
Alternator Replacement—2.5L Engine . . . . . . . . . . . 8
Alternator Replacement—3.0L Engine . . . . . . . . . . . 9
Alternator Replacement—3.3L Engine
. . . . . . . . . . 10
General Information
. . . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL INFORMATION
This section will cover alternator replacement only.
Information covering alternator on-vehicle testing and
diagnosis
can
be
found
in
Group
8A,
Battery/Starting/Charging Systems Diagnostics. To
identify the alternator, refer to the Alternator Specifi-
cation chart at the rear of this section.
These alternators are not intended to be disas-
sembled for service. It must be replaced as an
assembly.
ALTERNATOR REPLACEMENT—2.5L ENGINE
Removal and repositioning of A/C Compressor with-
out disconnecting refrigerant lines is necessary on
some models to gain access to alternator.
(1) Disconnect battery negative cable (Fig. 1).
(2) If Equipped With air conditioning:
(a) Remove the A/C drive belt. Refer to Group 7,
Cooling System.
(b) Remove the four bolts retaining the A/C com-
pressor to the mounting bracket (Fig. 2).
(c) Do not disconnecting the A/C refrigerant lines,
position the A/C compressor to allow alternator re-
moval.
WARNING: THE A/C REFRIGERANT SYSTEM IS UN-
DER PRESSURE EVEN WHEN THE ENGINE IS OFF.
REFER TO THE SAFETY PRECAUTIONS AND WARN-
INGS SECTION IN HEATING AND A/C, GROUP 24,
BEFORE PERFORMING ANY SERVICE OPERATION.
(3) Remove the alternator drive belt. Refer to Group
7, Cooling System.
(4) Remove the two alternator mounting bolts (Fig.
3) and position the alternator to gain access to all the
wire connectors. If equipped with a :
• BOSCH ALTERNATOR. Remove B+ terminal nut,
field terminal nuts, and ground harness hold down
nuts (Fig. 4). Remove wire connector assembly.
• NIPPONDENSO ALTERNATOR. Remove nuts from
field
terminals,
ground
terminal,
wire
harness
Fig. 3 Remove or Install Mounting Bolts
Fig. 1 Remove Battery Negative (-) Cable
Fig. 2 A/C Compressor Removal and
Installation—2.5 L Engine
8B - 8
BATTERY/STARTER/ALTERNATOR SERVICE
.
and B+ terminal (Fig. 5). B+ terminal nut must be
removed last to prevent damage to terminal insulator.
(5) Remove the alternator from the vehicle.
(6) For
installation,
reverse
above
procedures.
Torque all fasteners. Refer to the TORQUE SPECIFI-
CATIONS chart at the rear of this group.
ALTERNATOR REPLACEMENT—3.0L ENGINE
(1) Disconnect battery negative cable (Fig. 1).
(2) Remove alternator drive belt. Refer to Group 7,
Cooling System.
(3) Remove the alternator mounting bolts and sepa-
rate the alternator from the mounting bracket (Fig. 6).
(4) Remove the B+ terminal nut, field terminal nuts,
and ground/wire harness hold-down nuts. Remove wire
connectors.
(5) Remove the alternator from the vehicle.
(6) For
installation,
reverse
above
procedures.
Torque all fasteners. Refer to the Torque Specifications
chart at the back of this group.
Fig. 4 Remove or Install Wire Connector
Assembly—Bosch Alternator
Fig. 5 Remove or Install Wire Connector
Assembly—Nippondenso Alternator
Fig. 6 Remove or Install Alternator Mounting
Bolts—3.0L Engine
Fig. 7 Support Bracket for Alternator Tensioner
Power Steering Bracket
.
BATTERY/STARTER/ALTERNATOR SERVICE
8B - 9
ALTERNATOR REPLACEMENT—3.3L ENGINE
(1) Disconnect battery NEGATIVE cable (Fig. 1).
(2) Remove alternator drive belt. Refer to Group 7,
Cooling System.
(3) Loosen, but do not remove the nut on the support
bracket at exhaust manifold (Fig. 7).
(4) Remove the alternator tensioner power steering
bracket bolt.
(5) Remove the tensioner stud nut and the tensioner
(Fig. 8).
(6) Remove the alternator mounting bolts.
(7) Remove and position the power steering reser-
voir from the alternator mounting bracket. Do not
remove the hoses from the reservoir.
(8) Remove the three alternator support bracket
bolts (Fig. 7).
(9) Remove intake plenum-to-alternator mounting
bracket bolt.
(10) Remove alternator support bracket (Fig. 8).
(11) Position alternator and remove alternator wir-
ing.
(12) Remove alternator.
(13) For installation, reverse above procedures.
Torque all fasteners. Refer to the Torque Specifications
chart at the back of this group.
SPECIFICATIONS
Fig. 8 Alternator/Support Bracket—3.3L Engine
STARTER/BATTERY
8B - 10
BATTERY/STARTER/ALTERNATOR SERVICE
.
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