This answer covers:
2005 Chrysler 300 6cyl VIN "G" 3.5L SFI HO (72% of 2005 300's)
2005 Chrysler 300 6cyl VIN "R" 2.7L MFI DOHC (28% of 2005 300's)
2005 Dodge Magnum 5.7L engine
Alternator
Removal & Installation
WARNING - Precautions Section:
Disconnect negative cable from battery before removing battery output wire (b+ wire) from alternator. Failure to do so can result in injury or damage to electrical system.
2.7L Engine
- Before servicing the vehicle, refer to the Precautions section.
- Disconnect negative battery cable.
- Remove alternator drive belt.
- Disconnect alternator field circuit plug.
- Remove B+ terminal nut and wire.
- Remove 2 lower mounting bolts.
- Remove alternator.
To install:
- Install alternator.
- Install upper bolt mounting bolt.
- Install 2 lower mounting bolts.
- Tighten bolts to 48 ft. lbs. (65 Nm).
- Install B+ terminal nut and wire. Tighten nut to 115 inch lbs. (13 Nm).
- Connect alternator field circuit plug.
- Install alternator drive belt.
- Connect negative battery cable.
3.5L Engines
- Before servicing the vehicle, refer to the Precautions section.
- Disconnect negative battery cable.
- Remove alternator drive belt.
- Remove bracket bolts.
- Remove upper mounting bolt.
- Raise and support vehicle.
- Remove middle splash pan.
- Disconnect alternator field circuit plug.
- Remove B+ terminal nut and wire.
- Remove lower mounting bolts.
- Remove alternator.
To install:
- Install alternator.
- Install lower mounting bolts. Loosen install the upper mounting bolt.
- Tighten lower mounting bolts to 48 ft. lbs. (65 Nm).
- Connect alternator field circuit plug.
- Install B+ terminal nut and wire. Tighten nut to 115 inch lbs. (13 Nm).
- Install middle splash pan.
- Lower vehicle.
- Remove loose installed upper bolt.
- Install bracket and bracket bolt.
- Install upper mounting bolt and bracket.
- Tighten upper mounting bolt to 48 ft. lbs. (65 Nm).
- Tighten the bracket bolt to 40 ft. lbs. (54 Nm).
- Install alternator drive belt.
- Connect negative battery cable.
5.7L Engines
- Before servicing the vehicle, refer to the Precautions section.
- Disconnect negative battery cable at battery.
- Remove alternator drive belt.
- Raise and support vehicle.
- Unsnap plastic insulator cap from B+ output terminal.
- Remove B+ terminal mounting nut at rear of alternator. Disconnect terminal from alternator.
- Disconnect field wire connector at rear of alternator by pushing on connector tab.
- Remove alternator support bracket nut and bolt. Remove support bracket. See Figure 1.
- Remove 2 alternator mounting bolts. See Figure 2.
- Remove alternator from vehicle.
Fig. 1 Alternator Support Bracket - 5.7L engine
Fig. 2 Alternator Mounting Bolts - 5.7L engine
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