Charging System - Generators & Regulators: Removal & Installation Dodge Intrepid II

REMOVAL & INSTALLATION

Removal & Installation (2.0L Sebring Coupe)

1. Raise and support vehicle. Remove passenger side splash shield. Disconnect negative battery cable. On models equipped with cruise control, disconnect vacuum hose from speed control assembly. Remove 2 bolts securing speed control assembly lower bracket. Reposition speed control assembly aside.
2. On all models, remove generator BAT terminal nut and wire. Loosen, but DO NOT remove, adjusting "T" bolt. Loosen, but DO NOT remove, pivot bolt. Loosen adjusting bolt to allow removal of generator drive belt. Disconnect generator field circuit connector. see scheme 1
3. Remove adjusting "T" bolt and pivot bolt. Remove generator through wheel well. To install, reverse removal procedure. Tighten generator drive belt to proper specification. See «BELT TENSION»(ref-3590-S01260527212000051100000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-3590-S20184134402000051100000).

Scheme 5

Removal & Installation (2.0L Breeze & Stratus)

1. Disconnect negative battery cable from remote negative terminal on shock tower. Disconnect generator field circuit connector. see scheme 1 Remove BAT terminal nut and wire. Loosen, but DO NOT remove, adjusting "T" bolt. Loosen, but DO NOT remove, pivot bolt. Loosen adjusting bolt to allow removal of generator drive belt. Remove generator drive belt.
2. Remove "T" bolt and pivot bolt. DO NOT lose pivot bolt spacer. Release generator from mounting bracket and move it toward passenger head light bucket. Remove generator from head light bucket area. To install, reverse removal procedure. Tighten generator drive belt to proper specification. See «BELT TENSION»(ref-3590-S01260527212000051100000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-3590-S20184134402000051100000).

Scheme 6

Removal & Installation (2.0L Neon)

1. Disconnect negative battery cable. Loosen, but DO NOT remove generator adjustment nut. Raise and support vehicle with front wheels turned fully to right. Remove plastic lower splash shield. Disconnect generator field circuit connector by pushing Red locking tab. see scheme 2 Remove BAT terminal nut and wire.
2. Loosen, but DO NOT remove, pivot bolt. Remove generator drive belt (generator spill shield does not need to be removed). Remove 3 mounting pivot bracket bolts. Remove pivot bolt and bracket. Holding generator in one hand, remove adjustment nut and slide generator off "T" bolt ("T" bolt does not need to be removed).
3. Lower generator and remove through wheel well. Tighten generator drive belt to proper specification. See «BELT TENSION»(ref-3590-S01260527212000051100000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-3590-S20184134402000051100000).

Removal & Installation (2.4L)

1. Disconnect negative battery cable from remote negative terminal on shock tower. Disconnect generator field circuit connector. see scheme 1 Remove BAT terminal nut and wire. Loosen, but DO NOT remove, adjusting "T" bolt. Loosen, but DO NOT remove, pivot bolt. Loosen adjusting bolt to allow generator drive belt removal. Remove generator drive belt.
2. Remove "T" bolt and pivot bolt. Remove ABS brake unit by removing two lower plate mounting bolts. Remove coolant overflow bottle. Remove generator by sliding generator under air conditioning lines towards passenger side of vehicle. To install, reverse removal procedure. Tighten generator drive belt to proper specification. See «BELT TENSION»(ref-3590-S01260527212000051100000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-3590-S20184134402000051100000).

Scheme 7

Removal & Installation (2.5L Avenger)

1. Raise and support vehicle. Disconnect negative battery cable. Remove passenger side splash shield. On vehicles equipped with cruise control, remove vacuum hoses from cruise control vacuum reservoir. Remove vacuum reservoir. On all models, remove power steering pump cover. Remove A/C compressor drive belt. Remove power steering and generator drive belt.
2. Remove air intake hose. Disconnect (Throttle Position Sensor (TPS), Idle Air Control (IAC) motor harness connectors and vacuum hose from throttle body assembly. Remove throttle body assembly. Disconnect power steering oil pressure switch, oxygen sensors, Intake Air Temperature (IAT) sensor and fuel injectors harness connectors. Reposition control wiring harness aside.
3. Disconnect accelerator cable connection and intake manifold plenum vacuum hoses. Remove Manifold Absolute Pressure (MAP) sensor from intake manifold plenum. Remove Exhaust Gas Recirculation (EGR) pipe connection, EGR valve and transducer assembly from intake manifold plenum. Remove bolts securing intake manifold plenum. Remove intake manifold plenum. Remove upper generator bracket. Remove intake manifold plenum stay.
4. Disconnect generator field circuit connector. see scheme 1 Remove generator. Replace all gaskets with new. To install, reverse removal procedure. Tighten generator drive belt to proper specification. See «BELT TENSION»(ref-3590-S01260527212000051100000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-3590-S20184134402000051100000).

Scheme 8

Removal & Installation (2.5L Cirrus, Sebring Convertible & Stratus)

1. Disconnect negative battery cable from remote negative terminal on shock tower. Disconnect generator field circuit connector. see scheme 1or see scheme 2. Remove BAT terminal nut and wire. Loosen, but DO NOT remove, generator top mounting ear bolt. Loosen, but DO NOT remove, pivot bolt. Loosen adjusting bolt on idler/tensioner pulley to allow removal of generator drive belt. Remove generator drive belt.
2. Remove pivot bolt. DO NOT lose pivot bolt spacer. Remove generator top mounting ear bolt. Remove upper generator bracket. Remove generator. To install, reverse removal procedure. Tighten generator drive belt to proper specification. See «BELT TENSION»(ref-3590-S01260527212000051100000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-3590-S20184134402000051100000).

Scheme 9

Removal & Installation (2.7L)

1. Disconnect negative battery cable. Raise and support vehicle. Remove lower plastic splash shield. Remove transmission cooler and reposition transmission cooler aside. Remove lower radiator crossmember support and position a jackstand under radiator for support. Loosen, but DO NOT remove, adjusting "T" bolt. Loosen, but DO NOT remove, pivot bolt. Remove generator drive belt.
2. Disconnect generator field circuit connector. see scheme 3 Remove BAT terminal nut and wire. Remove pivot bolt. Do not loose pivot bolt spacer. Remove generator. Tighten generator drive belt to proper specification. See «BELT TENSION»(ref-3590-S01260527212000051100000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-3590-S20184134402000051100000).

Removal & Installation (3.2L & 3.5L)

1. Disconnect negative battery cable. Loosen, but DO NOT remove, lower mounting bolt. Loosen, but DO NOT remove, pivot bolt. Loosen belt adjustment bolt. Remove generator drive belt. Remove bracket, lower mounting bolt and pivot bolt. Remove generator. Disconnect generator field circuit connector. see scheme 4 Disconnect BAT terminal nut and wire.
2. To install, reverse removal procedure. Tighten generator drive belt to proper specification. See «BELT TENSION»(ref-3590-S01260527212000051100000) under ADJUSTMENTS. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-3590-S20184134402000051100000).