How to Replace Alternator 2008-2020 Dodge Grand Caravan

Introduction

This tutorial provides step-by-step instructions on how to replace the alternator in a 2008-2020 Dodge Grand Caravan. Replacing a failing alternator is essential for maintaining your vehicle's battery and electrical systems. This guide is particularly useful for owners of the 2014 Dodge Grand Caravan SE 3.6L, but the process is applicable to all models from 2008 to 2020.

Step 1: Prepare the Vehicle

• Disconnect the Battery

  • Locate the negative battery terminal on the driver's side of the engine compartment.
  • Use a 10mm socket or wrench to loosen the nut. Remove it from the terminal and set it aside to prevent any electrical connection.

• Drain the Coolant

  • Position a drain pan under the radiator.
  • Find the red radiator petcock on the driver's side and turn it counterclockwise using a flathead screwdriver or pliers to drain the coolant. Do not remove it completely; just loosen it to control the flow.
  • Remove the radiator cap to facilitate faster drainage.

Step 2: Remove Components for Access

• Close the Radiator Petcock

  • After draining, ensure the petcock is snug but do not overtighten.

• Remove the Coolant Overflow Tank

  • Disconnect the hose from the radiator cap fitting by removing it from its retainers.
  • Pull the coolant overflow tank straight up to remove it.

• Disconnect Electrical Connectors

  • On the passenger side near the fan assembly, disconnect the electrical connector by unlocking it with a small screwdriver or pry tool.
  • Locate and disconnect the wire container holding the previously disconnected wire.

• Remove the Upper Radiator Hose

  • Pinch the clamp and slide it off the hose. Set the hose aside.

• Remove the Fan Assembly

  • Press the clips on both sides of the radiator to unlock the fan assembly. Lift it up, disconnecting it from the wiring harness.

Step 3: Access the Alternator

• Remove the Wheel

  • Use a 19mm socket to remove the five lug nuts and take the wheel off.

• Remove the Splash Shield

  • Use a trim tool to pop off the push clips securing the splash shield.
  • Remove any 10mm bolts securing the shield.

• Release the Tension on the Serpentine Belt

  • Use a 3/8 inch drive ratchet to turn the tensioner counterclockwise and slip the belt off.

Step 4: Remove the Alternator

• Disconnect the Alternator Wires

  • Unplug the gray connector from the back of the alternator by flipping the red locking tab and pressing the connector.
  • Remove the nut securing the main power wire with a 13mm wrench or socket.

• Remove the Alternator Bolts

  • Remove the plastic shield from the alternator by unscrewing two nuts with a 13mm socket.
  • Use a deep 13mm socket to remove the two bolts securing the alternator.
  • Finally, remove the last mounting nut with an E7 inverted torx socket.

• Take Out the Alternator

  • Carefully lift the alternator out, ensuring you do not damage the radiator.

Step 5: Install the New Alternator

• Position the New Alternator

  • Slide the new alternator into place, ensuring it aligns with the mounting points.

• Secure the Alternator

  • Start by installing the bottom stud and then the top bolts. Do not fully tighten yet to allow for adjustments.
  • Once positioned, torque the mounting hardware to 18 ft-lbs.

• Reconnect the Electrical Components

  • Attach the main power wire and secure it with the new mounting nut. Ensure it is snug but avoid overtightening to prevent damage.

Step 6: Reassemble the Components

• Reinstall the Fan Assembly

  • Slide the fan assembly back into place, ensuring it secures to the radiator properly.
  • Reconnect the electrical harness and ensure it locks in place.

• Reconnect the Upper Radiator Hose

  • Position the hose back and secure the clamp.

• Reinstall the Splash Shield and Wheel

  • Secure the splash shield with push clips and bolts, then put the wheel back on and torque the lug nuts to 100 ft-lbs in a cross pattern.

Step 7: Refill the Coolant System

• Fill the Cooling System

  • Use a spill-proof funnel to fill the radiator with coolant until it stops bubbling, ensuring no air pockets remain.

• Start the Engine

  • Turn on the engine and set the heater to the hottest setting. Monitor the temperature gauge to ensure it doesn’t exceed the halfway mark.

• Final Checks

  • After reaching operating temperature, check the coolant overflow tank and add coolant if necessary. Replace the radiator cap securely.

Conclusion

Replacing the alternator in your Dodge Grand Caravan can be accomplished with the right tools and careful attention to detail. Always remember to check all connections and ensure everything is secured properly before driving. If you encounter any issues, consult a professional mechanic for assistance.