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Charging System - Generators & Regulators: Removal & Installation Dodge Pickup R2500

Charging System 8 illustrations ~745 words

Removal

The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray.

  1. Remove battery.
  2. Pry sensor straight up from battery tray mounting hole to gain access to electrical connector.
  3. Disconnect sensor from engine wire harness electrical connector.

Installation

  1. Pull electrical connector up through mounting hole in top of battery tray.
  2. Connect sensor.
  3. Snap sensor into battery tray.
  4. Install battery.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

Removal (3.7L & 4.7L)

WARNINGDisconnect negative cable from battery before removing battery output wire (B+ wire) from generator. Failure to do so can result in injury or damage to electrical system.
  1. Disconnect negative battery cable at battery.
  2. Remove generator drive belt.
  3. Unsnap plastic insulator cap from B+ output terminal. (Scheme 1)
  4. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator.
  5. Disconnect field wire connector at rear of generator by pushing on connector tab.
  6. Remove 1 rear vertical generator mounting bolt. (Scheme 2)
  7. Remove 2 front horizontal generator mounting bolts.
  8. Remove generator from vehicle.

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2

Removal (5.7L)

WARNINGDisconnect negative cable from battery before removing battery output wire (B+ wire) from generator. Failure to do so can result in injury or damage to electrical system.
  1. Disconnect negative battery cable at battery.
  2. Remove generator drive belt.
  3. Unsnap plastic insulator cap from B+ output terminal.
  4. Remove B+ terminal mounting nut at rear of generator. Disconnect field wire connector at rear of generator by pushing on connector tab.
  5. Disconnect field wire connector at rear of generator by pushing on connector tab.
  6. Remove generator support bracket nuts and bolt and remove support bracket. (Scheme 3)
  7. Remove 2 generator mounting bolts. (Scheme 4)
  8. Remove generator from vehicle.

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Removal (5.9L Diesel)

WARNINGDisconnect negative cable from battery before removing battery output wire (B+ wire) from generator. Failure to do so can result in injury or damage to electrical system.
  1. Disconnect both negative battery cables at both batteries.
  2. Remove generator drive belt.
  3. Unsnap plastic insulator cap from B+ output terminal.
  4. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator.
  5. Disconnect field wire connector at rear of generator by pushing on connector tab.
  6. Remove upper mounting bracket bolt. (Scheme 5)
  7. Remove lower mounting bracket bolt and nut.
  8. Remove generator from vehicle.

Scheme 5

Scheme 5
Scheme 5

Removal 5.9L (Gas)

WARNINGDisconnect negative cable from battery before removing battery output wire (B+ wire) from generator. Failure to do so can result in injury or damage to electrical system.
  1. Disconnect both negative battery cables at both batteries.
  2. Remove generator drive belt.
  3. Unsnap plastic insulator cap from B+ output terminal. (Scheme 6)
  4. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator.
  5. Disconnect field wire connector at rear of generator by pushing on connector tab.
  6. Remove 1 upper mounting bracket bolt. (Scheme 7)
  7. Remove 1 lower mounting bracket bolt and nut.
  8. Remove generator from vehicle.

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Removal (8.0L)

WARNINGDisconnect negative cable from battery before removing battery output wire (B+ wire) from generator. Failure to do so can result in injury or damage to electrical system.
  1. Disconnect negative battery cable at battery.
  2. Remove generator drive belt.
  3. Unsnap plastic insulator cap from B+ output terminal.
  4. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator.
  5. Disconnect field wire connector at rear of generator by pushing on connector tab.
  6. Remove upper mounting bolt and nut. (Scheme 8)
  7. Remove lower mounting bolt.
  8. Remove the generator from vehicle.

Scheme 8

Scheme 8
Scheme 8

Installation (3.7L & 4.7L)

  1. Position generator to engine and install 2 horizontal bolts and 1 vertical bolt.
  2. Tighten all 3 bolts. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  3. Snap field wire connector into rear of generator.
  4. Install B+ terminal eyelet to generator output stud. Tighten mounting nut. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  5. Install generator drive belt.
  6. Install negative battery cable to battery.

Installation (5.7L)

  1. Position generator to engine and install 2 mounting bolts.
  2. Tighten bolts. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  3. Position support bracket to front of generator and install bolt and nuts. Tighten bolts/nuts. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  4. Snap field wire connector into rear of generator.
  5. Install B+ terminal eyelet to generator output stud. Tighten mounting nut. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  6. Install generator drive belt. See «ACCESSORY DRIVE»(ref-189655) .
  7. Install negative battery cable to battery.

Installation (5.9L Diesel)

  1. Position generator to upper and lower mounting brackets and install upper bolt and lower bolt/nut. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  2. Tighten all bolts/nut. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  3. Snap field wire connector into rear of generator.
  4. Install B+ terminal eyelet to generator output stud. Tighten mounting nut.
  5. Install generator drive belt.
  6. Install both negative battery cables to both batteries.

Installation (5.9L Gas)

  1. Position generator to engine and install upper bolt and lower bolt/nut.
  2. Tighten all bolts/nut. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  3. Snap field wire connector into rear of generator.
  4. Install B+ terminal eyelet to generator output stud. Tighten mounting nut. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  5. Insatll generator drive belt.
  6. Install negative battery cable to battery.

Installation (8.0L)

  1. Position generator to engine and install lower bolt and upper bolt/nut. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  2. Tighten all bolts/nuts. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  3. Snap field wire connector into rear of generator.
  4. Install B+ terminal eyelet to generator output stud. Tighten mounting nut. See «TORQUE SPECIFICATIONS»(ref-165616-S04050856572004083000000) .
  5. Install generator drive belt.
  6. Install negative battery cable to battery.

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