alternator 4801624AD P04801624AD RL801624AD 68272108AA 11570N for Chrysler 200 Dodge Avengers

Installation Guide for Chrysler & Dodge Avenger 12V Alternators

I. Preparation and Safety (Mandatory)

II. Removal of the Old Alternator (Reverse Reference)

1. Disconnect Wiring:

• First, disconnect the voltage regulator plug (press the tab to unlock).

• Then, remove the B+ terminal nut (10–14mm) and disconnect the output cable. Place an insulating cap over the cable end.

2. Loosen Belt:

• Use a 一对一 tool to rotate the automatic tensioner.

• Release tension and remove the belt. Do not pry against the belt or pulley edges to avoid damage.

3. Remove Bolts:

• Unscrew the mounting bolts in the order: Top → Bottom → Pivot.

• Remove the alternator.

• Note: If space is limited, temporarily loosen the right-side engine mount bolt to slightly reposition the engine.

4. Clean:

• Clean oil, rust, and old gasket residue from the mounting surfaces to ensure a reliable ground and secure fit.

III. Installation of the New Alternator (Core Steps)

• Place the new alternator into the bracket.

• Insert the main mounting bolts and the pivot bolt. Tighten them by hand first to ensure the threads are aligned and not cross-threaded. Do not fully tighten yet.

• Verify that the mounting surfaces and lugs are flush. Replace the dowel pin/bushing if necessary.

• Route the belt according to the factory diagram. Confirm all grooves are aligned with the pulleys; ensure there is no misalignment or floating.

• Rotate the tensioner to reset and slowly release the tension.

• Automatic Tensioner: Ensure it can oscillate freely.

• Manual Adjustment: Press the middle of the belt with your thumb. Deflection should be controlled between 10–15mm (varies by belt length).

• Fine-tune the alternator position so the belt is coplanar with the crankshaft and accessory pulleys to eliminate the risk of uneven wear.

• Tighten to the specified torque:

• Main Mounting Bolts: 40–54 N·m

• Pivot Bolt: 30–41 N·m

• B+ Terminal Nut: 10 N·m (approx. 88.5 in·lbs)

• Tensioner Bolt: 30–40 N·m

• Apply a small amount of thread locker to the B+ terminal and reinstall the protective cover.

• Connect the B+ thick cable first, then plug in the regulator connector. Ensure the clip locks securely.

• Secure the harness with zip ties, routing it away from the fan, belt, and exhaust manifold.

• Precautions for Installing Chrysler & Dodge Avenger 12V Alternators

• When replacing or installing a 12V alternator in Chrysler and Dodge Avenger models, strict adherence to the following core precautions is mandatory. This is due to the compact engine bay layout (specifically for 2.4L and 3.6L engines) and the implementation of electronically controlled charging systems. Failure to comply may result in rework, damage to expensive electronic components, or safety hazards.

• I. Electrical Safety (Critical)

• 1. Strictly Prohibited: Battery Polarity Reversal

• Operation: When installing the battery, confirm the positive (+) and negative (-) terminals are correct.

• Consequence: The rectifier diodes inside Chrysler/Dodge alternators are extremely fragile and lack reverse polarity protection. If the terminals are reversed, the diodes will instantly short-circuit and potentially explode, destroying the alternator. This often also damages the vehicle's Power Management Module (PMM) or Engine Control Unit (ECU), resulting in high repair costs.

• 2. Must Disconnect Negative Terminal First

• Operation: Before removing or installing any wiring, always disconnect the negative (-) battery terminal first.

• Reason: The alternator output terminal (B+) is directly connected to the positive battery terminal. During operation, if a wrench or metal tool contacts both the B+ terminal and the engine block (ground) simultaneously, a violent arc flash will occur, which may cause burns or a wiring harness fire.

• 3. Strictly Prohibited: "Spark" Testing

• Warning: Do not use the traditional method of scraping a wire against the engine block to check for sparks to test if the alternator is generating power.

• Consequence: This creates an instantaneous high-voltage pulse that can destroy the precision electronic components inside the voltage regulator or damage the vehicle's CAN bus system.

• II. Mechanical Installation (Determines Lifespan and Access)

• 1. Space Constraints – Do Not Force Removal

• Challenge: The alternator installation location in the Dodge Avenger and some Chrysler models (e.g., 200, Sebring) is very tight. Accessing the lower mounting bolt and the B+ terminal is particularly difficult.

• Solutions:

• The use of a Universal Joint (U-joint) and long extension bars is likely necessary.

• On some 2.4L models, it may be necessary to first remove the intake manifold or air filter box to create enough working space.

• Never pry hard on the alternator, as this can damage the aluminum bracket or the engine mount rubber.

  
  
  
  

• References：

• Source Attribution and Verification References

• The precautions listed are a synthesized technical summary derived from multiple authoritative sources and do not originate from a single document. Below is the source traceability and verification evidence prioritized by authority, facilitating itemized verification.

• I. Core Authoritative Sources (Directly Verifiable)

• Source Type	Specific Document / Standard	Publisher	Corresponding Core Content	Access Path
  Chrysler/Dodge OEM Service Manual	Dodge Avenger 2.4L/3.6L Engine Service Manual (Alternator Chapter)	Stellantis Group (formerly FCA)	Power disconnection procedure, B+ terminal definition, main/pivot bolt torque, belt routing and tensioning specifications, rectifier diode protection requirements.	Stellantis official website after-sales section, authorized service stations, Mopar electronic service systems, ManualsLib, and other manual platforms.
  Chrysler/Dodge OEM Service Manual	Chrysler 200/Sebring Alternator Assembly Installation Specifications	Stellantis Group	Overrunning Alternator Pulley (OAP) inspection standards, installation positioning requirements, wiring harness insulation specifications.	Chrysler parts catalog or Mopar electronic service systems.
  Industry Standard	Technical Conditions for Automobile Alternator Repair (QC/T 518)	National Technical Committee for Automotive Standardization	Charging voltage range (13.8–14.7V), start intervals and duration, gear meshing technical requirements.	National Standard Database, China Automotive Industry Association website.
  Industry Standard	Technical Requirements for Installation of Heavy-Duty Automobile Electrical Systems (QC/T 413)	National Technical Committee for Automotive Standardization	Battery reverse connection protection, wiring harness securing and insulation, short-circuit risk prevention and control.	National Standard Database.
  Component Manual	Alternator Installation and Maintenance Guide for Chrysler/Dodge models (e.g., Bosch, Delphi, etc.)	Bosch, Delphi, etc.	Overrunning pulley one-way rotation/reverse lock detection method, bearing abnormal noise judgment standard.	After-sales data on component manufacturer websites, Chrysler authorized parts suppliers.

• II. Content Traceability Explanation

• Electrical Safety Rules (Reverse connection prohibition, disconnect negative first, strictly prohibited spark testing): Derived from the mandatory power disconnection process and terminal specifications in the Chrysler/Dodge OEM manuals, while also complying with the electrical connection safety guidelines in QC/T 518.

• Mechanical Installation Points (Hand-threading bolts to prevent stripping, belt tension 10–15mm deflection, coaxiality check): Based on installation specifications tailored to the material properties of Chrysler/Dodge engine brackets (cast aluminum/cast iron), referencing OEM torque parameters (main bolts 40–54 N·m, pivot bolts 30–41 N·m).

• Component Inspection Standards (Overrunning pulley test, flywheel ring gear check, insulation securing): Integrated from Chrysler/Dodge OEM assembly requirements and component technical specifications to ensure no interference or short-circuit risks after installation.

• Trial Operation Judgment (Charge indicator light status, voltage 13.8–14.7V, abnormal noise identification): Based on QC/T 518 charging performance indicators and Chrysler/Dodge OEM fault diagnosis procedures to ensure the normal operation of the power generation system.

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