alternator RL801624AD 4801624AD 11570 421000-0770 4210000770 for Chrysler 200 Automatic AC Generator

Chrysler Voyager Generator Installation Method

• Preparation: Ensure the vehicle is turned off and disconnect the negative battery cable. Prepare tools such as wrenches and sockets.

• Removing the Old Generator:

• Locate the belt tensioner at the front of the engine. Use a socket and ratchet wrench to rotate the tensioner clockwise to loosen the drive belt, and then remove the belt from the generator pulley.

• Locate the wiring harness connections on the back of the generator. Use a socket and ratchet wrench to loosen the five connecting nuts and remove the wiring harness.

• Locate the two bolts fixing the generator to the mounting bracket, one at the top and one at the bottom. Use a socket and ratchet wrench to loosen and remove these two bolts, and then take the old generator out of the engine compartment.

• Installing the New Generator:

• Install the new generator onto the mounting bracket using the original two mounting bolts and tighten them with a socket and ratchet wrench.

• Install the wiring harness connector on the rear of the generator. First, install the thicker wire onto the "B" terminal, and then install the other wires. Ensure the connections are correct, install the retaining nuts and tighten them.

• Use a socket and ratchet wrench to rotate the belt tensioner clockwise, fit the belt onto the generator pulley and other relevant pulleys, then release the tensioner to tension the belt.

• Inspection and Testing: Check that the generator is securely installed and that all electrical connections are correct. Reconnect the negative battery cable, start the vehicle, and check if the generator works normally.

Chrysler Crossfire Generator Installation Method

• Preparation: Disconnect the negative battery cable and remove the right side air inlet tube.

• Removing the Old Generator:

• Pull the tensioning pulley in a counterclockwise direction to remove the accessory drive belt from the generator pulley. Lock the tensioning pulley with a pin or slowly release the pulley after the belt is free.

• Remove the upper generator bolt, then remove the lower bolt, and reposition the generator to access the generator harness connectors.

• Remove the protective plastic cap from the generator B+ cable retaining nut, disconnect the generator B+ cable and the generator harness connectors from the rear of the generator, and then remove the generator.

• Installing the New Generator:

• Connect the generator B+ cable with the retaining nut and connect the generator harness connector. Tighten the generator B+ cable retaining nut to 15N・m (11ft・lbs).

• Install the protective plastic cap on the generator B+ cable nut, install the generator onto the mounting bracket, install the upper and lower generator mounting bolts, and tighten the generator mounting bolts to 42N・m (31ft・lbs).

• Install the accessory drive belt, install the right side air inlet tube, and connect the negative battery cable.

I. Safety Protection Category

1. Power Disconnection Operation Specifications: Before either disassembly or installation, the engine must be turned off and the negative battery cable disconnected. Wait for the residual electricity in the circuit to be exhausted before starting work to avoid the risks of short circuits, electric shocks, or accidental startup. Do not turn on the vehicle power supply during the entire operation to prevent false triggering of electrical components.

2. Personal and Vehicle Protection: Operators must wear gloves and goggles to avoid hand scratches from sharp components or contamination by oil stains. Lay a protective pad in the engine compartment to prevent tools and parts from falling and damaging the vehicle body paint, surrounding pipelines, or sensors.

3. Additional Protection for Special Models: When removing the right-side air inlet tube of the Crossfire model, pay attention to protecting the seals and sensors inside the air intake duct to avoid scratches by hard objects or dust entering the air intake system. After installation, check the tightness of the air inlet tube interface to prevent air leakage.

II. Component Inspection and Handling Category

1. Model and Condition Verification: Before installation, confirm that the model of the new generator is compatible with the vehicle (especially matching the engine displacement and electrical system parameters). Check that the generator has no cracks or deformation in appearance, no rust on the terminals, the internal bearings rotate smoothly without abnormal noise, and all components are complete (such as protective covers and fixing washers).

2. Cleaning and Preprocessing: Clean oil stains, rust, and dust from the generator mounting bracket, bolt threads, and terminals. If necessary, apply a small amount of anti-rust lubricant to the bolt threads (avoid contaminating the terminal contact surfaces). For the Crossfire model, clean the B+ cable connector to ensure good conductivity.

3. Marking and Recording of Old Components: When removing the old generator, clearly mark the wiring harness connection positions and bolt installation sequence (such as distinguishing between the top and bottom bolts of the Voyager model) by taking photos or making marks. This avoids incorrect wiring or reversed bolt installation when installing the new component.

III. Installation Operation Category

1. Bolt Tightening Specifications

• Tighten bolts strictly according to the torque specified for the model: For the Voyager model, the generator fixing bolts must be tightened to the standard torque specified in the manual to avoid vibration and displacement due to insufficient tightness or bracket deformation due to excessive tightness. For the Crossfire model, the torque for the B+ cable fixing nut is 15N・m (11ft・lbs), and the torque for the generator mounting bolts is 42N・m (31ft・lbs). A torque wrench must be used for precise operation.

• Ensure that washers are installed in the correct positions during bolt installation, and avoid omissions or reversals to prevent loose connections or poor conductivity.

2. Wiring Harness Connection Requirements

• Follow the wiring sequence of "thick wires first, thin wires later; main wires first, secondary wires later": First connect the generator's main power cable (such as the "B" terminal of the Voyager and the B+ cable of the Crossfire), then connect the control lines and sensor wiring harnesses. Ensure each terminal is securely connected without looseness or poor contact.

• Do not wrap the wiring harness around the generator pulley or high-temperature components to avoid being caught during operation or damaged due to high-temperature aging. Wrap exposed wiring parts with insulating tape to prevent short circuits and electric leakage.

3. Belt Installation and Tension Control

• When operating the belt tensioner (rotating clockwise for the Voyager and pulling counterclockwise for the Crossfire), use appropriate tools. Avoid brute force prying, which may cause damage to the tensioner spring or bearings. For the Crossfire model, lock the tensioner pulley with a pin or release the tension slowly when loosening it to prevent the tensioner from rebounding and causing injury.

• After installing the belt, check its tension: Press the middle of the belt by hand, and the deflection should be within a reasonable range (usually 10-15mm). An overly loose belt is prone to slipping, affecting power generation efficiency; an overly tight belt will accelerate the wear of the generator bearings and the belt, shortening their service life. At the same time, confirm that the belt is aligned with all pulleys without deviation or distortion.

4. Installation Key Points for Special Models

• When installing the wiring harness of the Voyager model, distinguish the connection position of the "B" terminal from other control lines to avoid generator burnout or vehicle electrical system failure due to incorrect connection.

• When installing the air inlet tube of the Crossfire model, ensure that the interface clamp is tightened properly and the seal fits well to prevent air intake leakage during engine operation, which may affect power performance and air-fuel ratio.

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