Here's a general outline. Specific steps might vary slightly depending on your exact model and any modifications:
Tools You'll Need:
* Socket wrench set (metric)
* Ratchet and extensions
* Wrenches (metric)
* Pliers (needle-nose are helpful)
* Jack and jack stands (essential for safety)
* Wheel chocks
* Battery terminal cleaner
* New alternator (make sure to get the correct one for your vehicle)
* Possibly a charging system tester (to verify proper operation after installation)
Procedure:
1. Safety First: Park on a level surface, engage the parking brake, and use wheel chocks. Raise the vehicle using a jack and securely support it with jack stands.
2. Disconnect the Battery: Disconnect the negative (-) battery cable first, then the positive (+) cable.
3. Access the Alternator: The alternator is typically located on the front of the engine, near the passenger side. Access may be somewhat limited depending on the engine accessories. You might need to remove some components to get to it easily. This could include:
* Air Intake Hose: Disconnect and move the air intake hose out of the way.
* Serpentine Belt: This is usually the biggest hurdle. You'll need to loosen the tensioner pulley to remove the serpentine belt. Consult a repair manual for your specific vehicle to determine the correct procedure for your tensioner (some use a wrench, others a special tool). Diagram your belt routing carefully *before* removing it.
* Wiring and Connections: Locate the alternator's wiring harness and disconnect the electrical connectors. Take pictures to remember where everything goes. Note the wiring before unplugging to avoid misconnections during reassembly.
* Alternator Mounting Bolts: The alternator is typically held in place by two or three bolts. Loosen and remove these bolts.
4. Remove the Alternator: Carefully remove the alternator from its mounting bracket. It might be a little heavy.
5. Install the New Alternator:
* Install the new alternator in the reverse order of removal.
* Ensure the alternator is correctly seated in its bracket.
* Tighten the mounting bolts securely.
* Reconnect the wiring harness connectors. Ensure that they are firmly seated and make good contact.
6. Reinstall Components: Carefully reinstall the serpentine belt, ensuring it's properly routed over all the pulleys. Reattach the air intake hose and any other components you removed.
7. Reconnect the Battery: Connect the positive (+) battery cable, then the negative (-) battery cable.
8. Test: Start the engine and check for any warning lights. Use a voltmeter or charging system tester to verify the alternator is charging the battery correctly. The voltage should be around 13.5-14.5 volts while the engine is running.
Important Considerations:
* Repair Manual: A repair manual specific to your 1993 Plymouth Voyager 3.3L V6 is highly recommended. It will provide detailed diagrams and instructions tailored to your vehicle. This will significantly reduce the chance of error and damage.
* Serpentine Belt Tensioner: Be careful when working with the serpentine belt tensioner. Improper handling can result in injury.
* Electrical Connections: Be meticulous when disconnecting and reconnecting electrical components. Incorrect connections can damage your vehicle's electrical system.
This is a general guide. Consult a repair manual for precise instructions and torque specifications for your specific vehicle. If you are not comfortable performing this repair yourself, it is best to take your vehicle to a qualified mechanic. Improper installation can lead to damage to your vehicle's electrical system and potentially serious injury.
