Operation CHARM: Car repair manuals for everyone.
Home >> Dodge and Ram >> 2004 >> Sprinter 2500 L5-2.7L DSL Turbo >> Repair and Diagnosis >> Starting and Charging >> Charging System >> Alternator >> Service and Repair
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

Or, hide this message: temporarily or permanently

Alternator: Service and Repair

REMOVAL

CAUTION:
- Disconnect negative cable from battery before removing battery output wire from generator. Failure to do so can result in injury.
- Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
- When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in Cooling System.

1. Disconnect and isolate negative battery cable.
2. Remove generator drive belt. Refer to Cooling System for procedure.
3. Raise and support vehicle.
4. Remove protective plastic cover from B+ stud at top of generator.
5. Remove nut securing battery output cable to B+ terminal at top of generator.
6. Unplug field terminal connector at rear of generator.

Generator Mounting - 2.7L Diesel:




7. Remove 4 generator mounting bolts (Torx-style #12 bit).
8. Remove generator from lower side of vehicle.

INSTALLATION
1. Raise and support vehicle.
2. Position generator to engine.
3. Install 4 generator mounting bolts. Refer to Torque Specifications.
4. Connect field terminal connector at rear of generator.
5. Install battery output cable and nut to B+ terminal at top of generator. Refer to Torque Specifications.
6. Install protective plastic cover to B+ stud at top of generator.
7. Lower vehicle.

CAUTION:
- Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
- When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in Cooling System.

8. Install generator drive belt. Refer to Cooling System for procedure.
9. Connect negative battery cable.
10. Check charging system for proper operation.
pro multis · About Operation CHARM