1995 Chrysler Cirrus 2.5L MFI 6cyl Repair Guides Charging System Alternator Auto...

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Todd Jacobs
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1 Page 1 of 9 SAVE 20% + GET A $10 GIFT CARD ON ONLINE SHIP-TO-HOME ORDERS OF $100 OR MORE. Use Code: 20TUNE10 See Details Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze TESTING REMOVAL & INSTALLATION Alternator TESTING See Figures 1 and 2 Fig. Fig. 1: Charging system schematic for Cirrus, Stratus, Sebring convertible and Breeze models Fig. Fig. 2: Charging system schematic for Sebring coupe and Avenger models Voltage Drop Test See Figures 3 and 4 These tests will show the amount of voltage drop across the alternator output wire from the alternator output (B+) terminal to the battery positive post. They will also show the amount of voltage drop from the ground (-) terminal on the alternator. A voltmeter with a 0-18 volt DC scale should be used for these tests. By repositioning the voltmeter test leads, the point of high resistance (voltage drop) can easily be found. Test points on the alternator can be reached by either removing the air cleaner housing or below by raising the vehicle. 1. Before starting the test, make sure the battery is in good condition and is fully charged. Check the conditions of the battery cables. 2. Start the engine, let it warm up to normal operating temperatures, then turn the engine OFF. 3. Connect an engine tachometer, following the manufacturer's directions. 4. Make sure the parking brake is fully engaged. 5. Start the engine, then place the blower on HIGH, and turn on the high beam headlamps and interior lamps. 6. Bring the engine speed up to 2,400 rpm and hold it there.

Page 2 of 9 7. To test the ground (-) circuitry, perform the following: A. Touch the negative lead of the voltmeter directly to the positive battery terminal. B.

2 Page 2 of 9 7. To test the ground (-) circuitry, perform the following: A. Touch the negative lead of the voltmeter directly to the positive battery terminal. B. Touch the positive lead of the voltmeter to the B+ output terminal stud on the alternator (NOT the terminal mounting nut). The voltage should be no higher than 0.6 volts. If the voltage is higher than 0.6 volts, touch the test lead to the terminal mounting stud nut, and then to the wiring connector. If the voltage is now below 0.6 volts, look for dirty, loose or poor connections at this point. A voltage drop test may be performed at each ground (-) connection in the circuit to locate the excessive resistance. Fig. Fig. 3: Alternator terminals for the 2.0L and 2.4L engines Fig. Fig. 4: Alternator terminals for the 2.5L engine 8. To test the positive (+) circuitry, perform the following: A. Touch the positive lead of the voltmeter directly to the negative battery terminal. B. Touch the negative lead of the voltmeter to the ground terminal stud on the alternator case (NOT the terminal mounting nut). The voltage should be no higher than 0.3 volts. If the voltage is higher than 0.3 volts, touch the test lead to the terminal mounting stud nut, and then to the wiring connector. If the voltage is now below 0.3 volts, look for dirty, loose or poor connections at this point. A voltage drop test may be performed at each positive (+) connection in the circuit to locate the excessive resistance. 9. This test can also be performed between the alternator case and the engine. If the test voltage is higher than 0.3 volts, check for corrosion at the alternator mounting points or loose alternator mounting. Output Voltage Test 1. Determine if any Diagnostic Trouble Codes (DTC'S) exist, as outlined in Driveability & Emissions Controls. 2. Before starting the test, make sure the battery is in good condition and is fully charged. Check the conditions of the battery cables. 3. Perform the voltage drop test to ensure clean and tight alternator/battery electrical connections. 4. Be sure the alternator drive belt is properly tensioned, as outlined in General Information & Maintenance. 5. A volt/amp tester equipped with both a battery load control (carbon pile rheostat) and an inductive-type pickup clamp (ammeter probe) will be used for this test. Make sure to follows all directions supplied with the tester. If you are using a tester equipped with an inductive-type clamp, you don't have to remove the wiring from the alternator. 6. Start the engine and let it run until it reaches normal operating temperature, then shut the engine OFF.

3 Page 3 of 9 7. Make sure all electrical accessories and lights are turned OFF. 8. Connect the volt/amp tester leads to the battery. Be sure the carbon pile rheostat control is in the OPEN or OFF position before connecting the leads. 9. Connect the inductive clamp (ammeter probe), following the instructions supplied with the test equipment. 10. If a volt/amp tester is not equipped with an engine tachometer, connect a separate tachometer to the engine. 11. Fully engage the parking brake. 12. Start the engine, then bring the engine speed up to 2,500 rpm. WARNING This load test must be performed within 15 seconds to prevent damage to the test equipment! 13. With the engine speed held at 2,500 rpm, slowly adjust the rheostat control (load) on the tester to get the highest amperage reading. Do not let the voltage drop below 12 volts. Record the reading. On certain brands of test equipment, this load will be applied automatically. Be sure to read the operating manual supplied with the test equipment before performing the test. 14. The ammeter reading must meet the minimum test amps specification of 75 amps. 15. Rotate the load control to the OFF position. 16. Continue holding the engine speed at 2,500 rpm. If the EVR circuitry is OK, the amperage should drop below amps. With all of the electrical accessories and vehicle lighting off, this could take several minutes of engine operation. 17. After the procedure is complete, remove the volt/amp tester. REMOVAL & INSTALLATION 2.0L DOHC Engine See Figure 5 1. Disconnect the negative battery cable. 2. Remove the right side under cover. 3. Remove the speed control vacuum reservoir and related components, as required for alternator access. 4. Remove the alternator drive belt. 5. Remove the alternator mounting bolts. 6. Remove the alternator top brace from the engine. 7. Disconnect the alternator wiring and remove the alternator from the vehicle. Fig. Fig. 5: Alternator assembly installation-2.0l DOHC engine 8. Install the alternator in position and connect the electrical harness. 9. Install the alternator top brace to the engine. 10. Install the alternator mounting bolts loosely. 11. Install the drive belt and adjust until the proper tension is achieved. Secure the lower alternator through-bolt nut to 45 ft. lbs. (61 Nm) and the alternator's upper lockbolt to 40 ft. lbs. (54 Nm). 12. Install the speed control vacuum reservoir and whatever related components were removed for alternator access. 13. Install the right side undercover. 14. Connect the negative battery cable. Start the engine and check the alternator for proper operation. 2.0L SOHC Engine See Figure 6

4 Page 4 of 9 1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding. 2. Unplug the field circuit from the alternator. 3. Remove the B+ terminal cover by spreading the cover with a small, flat bladed tool. 4. Remove the B+ nut and wire. 5. Loosen the adjusting bolt, but do not remove. 6. Loosen the pivot bolt and the adjusting bolt until the drive belt can be removed. 7. Remove the adjusting bolt and pivot bolt, but do not drop the spacer. 8. Remove the alternator by moving it toward the headlight bucket. Fig. Fig. 6: Alternator assembly installation-2.0l SOHC engine 9. Install the alternator into the bracket on the engine. 10. Reinstall the pivot bolt, but do not tighten. 11. Reinstall the adjusting bolt, but do not tighten. 12. Reconnect the B+ wire and install the retaining nut. Tighten the nut to 75 inch lbs. (9 Nm). 13. Reinstall the B+ terminal cover. 14. Reconnect the field circuit to the alternator. 15. Reinstall the drive belt, making sure it is correctly routed and seated on the alternator pulley. Do not tension the drive belt at this time. 16. Adjust the drive belt and tighten the adjusting bolt to 40 ft. lbs. (54 Nm). 17. Tighten the pivot bolt to 40 ft. lbs. (54 Nm). 18. Reconnect the negative battery cable. 2.4L Engine See Figure 7 1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding. 2. Unplug the field circuit from the alternator. 3. Remove the B+ terminal cover from by spreading the cover with a flat bladed tool. 4. Remove the B+ nut and wire. 5. Loosen the adjusting bolt, but do not remove. 6. Loosen the pivot bolt and the adjusting bolt until the drive belt can be removed. Remove the accessory drive belt. 7. Remove the adjusting bolt and pivot bolt. 8. Remove the ABS braking unit by removing the 2 lower plate mounting bolts. Leave all lines connected. 9. Remove the coolant overflow bottle. 10. Remove the alternator by sliding the alternator under the air conditioner lines towards the passenger side of the vehicle.

5 Page 5 of 9 Fig. Fig. 7: Alternator assembly installation-2.4l engine 11. Install the alternator into the bracket on the engine. 12. Install the adjusting and pivot bolts, but do not tighten at this time. 13. Connect the B+ wire and tighten the nut to 75 inch lbs. (9 Nm). 14. Reinstall the B+ terminal cover. 15. Reconnect the field circuit to the alternator. 16. Install the accessory drive belt. Be sure the drive belt is correctly routed on the engine and correctly seated on the alternator pulley. 17. Adjust the drive belt and tighten the adjusting bolt to 40 ft. lbs. (54 Nm). 18. Tighten the pivot bolt to 40 ft. lbs. (54 Nm). 19. Reinstall the ABS braking unit. Install and tighten the 2 lower plate mounting bolts. 20. Reinstall the coolant overflow bottle. 21. Reconnect the negative battery cable. 2.5L (VIN N) Engine See Figure 8 1. Disconnect the negative battery cable. 2. Remove the right side under cover. 3. Remove the speed control vacuum reservoir and related components as required for alternator access. 4. Remove the power steering pump cover. 5. Remove the A/C compressor drive belt. 6. Remove the alternator/power steering pump drive belt. 7. Remove the intake manifold plenum. 8. Remove the upper alternator bracket. 9. Remove the intake manifold plenum stay. 10. Detach the electrical connections at the alternator. 11. Unfasten the upper and lower bolts and remove the alternator. Be very careful not to damage neighboring components while removing the alternator. Fig. Fig. 8: Alternator assembly installation-2.5l engine (VIN N) 12. Connect the wiring to the alternator. 13. Place the alternator on its lower bracket and install the upper and lower bolts finger-tight. 14. Install the upper alternator bracket. 15. Install the alternator/power steering pump belt, making sure it is properly seated. 16. Adjust the drive belt to the correct tension using the belt adjuster, then tighten the upper mounting bolt to 16 ft. lbs. (22 Nm) and the lower mounting bolt to 30 ft. lbs. (41 Nm). 17. Install the intake manifold plenum. 18. Install the intake manifold plenum stay. 19. Install the A/C compressor drive belt. 20. Install the power steering pump cover. 21. Connect the negative battery cable. 22. Check the charging system operation. 2.5L (VIN H) Engine See Figures 9 through 19

Page 6 of 9 1. Disconnect the negative battery cable from the left strut tower.

accidentally grounding. 2. Unplug the field circuit from the alternator. 3. Remove the B+ terminal nut and wire. 4.

Loosen the adjusting bolt on the idler to allow removal of the alternator drive belt. 6. Loosen, but do not remove, the pivot bolt.

6 Page 6 of 9 1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding. 2. Unplug the field circuit from the alternator. 3. Remove the B+ terminal nut and wire. 4. Loosen the top mounting ear bolt. It may be necessary to remove the drive belt and lower alternator pivot bolt from under the vehicle. 5. Loosen the adjusting bolt on the idler to allow removal of the alternator drive belt. 6. Loosen, but do not remove, the pivot bolt. Use care not to lose the nut. Fig. Fig. 9: Disconnect the field coil terminal from the back of the alternator, then the B+ terminal nut and wire Fig. Fig. 10: Loosen the top mounting ear bolt Fig. Fig. 11: Location of the idler pulley locknut-the adjuster screw is to the side

Fig. 14: Loosen the lower pivot bolt while securing the nut with a wrench

7 Page 7 of 9 Fig. Fig. 12: Loosening the adjuster bolt from below the vehicle, to remove the drive belt Fig. Fig. 13: Removing the alternator drive belt Fig. Fig. 14: Loosen the lower pivot bolt while securing the nut with a wrench 7. Remove the pivot bolt, using care not to lose the spacer. 8. Remove the top mounting ear bolt. 9. For easier access, disconnect and move all wiring harnesses out of the way. 10. Remove the alternator upper bracket. 11. Remove the alternator from the vehicle. Fig. Fig. 15: It may be easier to remove the alternator lower pivot bolt from below the vehicle

Fig. 19: Remove the alternator from the vehicle 12.

8 Page 8 of 9 Fig. Fig. 16: Disconnect and move all wiring harnesses out of the way Fig. Fig. 17: Remove the alternator's upper mounting bracket bolts... Fig. Fig. 18:... then remove the upper mounting bracket Fig. Fig. 19: Remove the alternator from the vehicle 12. Install the alternator into the bracket on the engine. 13. Reinstall the alternator's upper mounting bracket and tighten the bolts. 14. Reinstall the pivot bolt, but do not tighten at this time.

9 Page 9 of Install the top mounting ear bolt, but do not tighten at this time. 16. Reconnect the B+ terminal wire and tighten the nut to 75 inch lbs. (9 Nm). Connect all wiring harnesses which were disconnected during removal. 17. Reconnect the field circuit to the alternator. 18. Reinstall the drive belt. Be sure the accessory drive belt is correctly routed on the engine and properly seated on the alternator pulley. 19. Adjust the drive belt and tighten the idler pulley bolt to 40 ft. lbs. (54 Nm). 20. Tighten the pivot bolt and top mounting ear bolt to 40 ft. lbs. (54 Nm). 21. Reconnect the negative battery cable. Back to Top

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