Alternator Removal and Replace on 200...

Alternator Removal and Replace on 2002 PT Cruiser 4Cyl

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Larry Adams

Missoula, MT

#1 Sep 8, 2006
Can anyone tell me what you must do to change a alternator on a 2002 PT Cruiser 4 cyl. Thanks Larry
Whitey

United States

#2 Sep 25, 2006
The PT utilizes a generator. I would recommend that you use a service guide if you attempt this procedure. It contains numerous illustrations and instructions for the sub procedures mentioned below.
Generator

Removal - 2.4L Turbo

The generator is located above the oil filter and axle shaft.

1. Disconnect the negative battery cable.
2. Remove the 2 bolts from the top of the heat shield on the generator.
3. Remove nut from the upper T-bolt adjustment bracket.
4. Raise vehicle and support.
5. Remove the right front wheel.
6. Remove the accessory drive splash shield.
7. Remove the lower heat shield bolt.
8. Remove the generator heat shield.
9. Unplug the field circuit from the generator.
10. Remove the B+ terminal nut and wire.
11. Loosen the accessory drive belt t-bolt.
12. Remove the pencil strut.
13. Loosen the lower generator pivot bolt.
14. Remove the generator belt, refer to the Cooling section for more information.
15. Remove the axle retaining nut.
16. Remove the lower control arm from the steering knuckle.
17. Remove the 2 bolts for the axle shaft bearing support.
18. Remove the axle shaft assembly. Put a container under the transmission to catch the transmission fluid from the transmission.
19. Remove the generator from the lower mounting bracket and set generator to the side.
20 . Remove the lower mounting bracket for the generator.
21. Remove generator through the axle shaft hole.

Installation - 2.4L Turbo

1. Install generator through the axle shaft hole in wheel well.
2. Put generator on upper t-bolt and loosen install the nut.
3. Install the lower mounting bracket for the generator to the block and tighten bolts to 54 N-m or 40 ft./lbs.
4. Loose install the lower pivot bolt for the generator.
5. Install the B+ terminal nut and wire and tighten nut to 11.3 N-m or 100 in./lbs.
6. Plug in the field circuit to the generator.
7. Install the axle shaft assembly.
8. Install the 2 bolts for the axle shaft bearing support and tighten bolts to 54.2 N-m or 40 ft./lbs.
9. Install the axle shaft into the steering knuckle.
10. Install the lower control arm to the steering knuckle and install the bolt and tighten bolts to 94.9 N-m or 70 ft./lbs.
11. Install the axle retaining nut and tighten nut to 244 N-m or 180 ft./lbs.
12. Install and tension the generator belt, refer to the Cooling section for more information.
13. Tighten the accessory drive belt t-bolt and tighten nut to 54 N-m or 40 ft./lbs.
14. Tighten the lower generator pivot bolt and tighten bolts to 54 N-m or 40 ft./lbs.
15. Install the pencil strut.
16. Install the generator heat shield.
17. Install the lower heat shield bolt and tighten bolt to 54.2 N-m or 40 ft./lbs.
18. Install the accessory drive splash shield.
19. Install the right front wheel.
20. Lower vehicle.
21. Tighten nut to the upper adjustment bracket and tighten to 25 N-m or 18 ft./ lbs.
22. Install the 2 bolts to the heat shield on the generator and tighten bolts to 4.5 N-m or 40 in./lbs.
23. Connect the negative battery cable.
Sally

Wake Forest, NC

#3 Sep 27, 2006
2002 pt cruiser 68k - i don't how to change it but i had to have my replaced while the car was still just under warranty.

sometimes the key would turn and sometimes it would not or it would turn and nothing happen.

had to have my car towed twice and the dealership tried to say nothing was wrong...since it didn't happen when it was in the shop.

had i driven it another week the warranty would have expired and i was not leaving there until they replaced it.

it has not happened again since the repair!

i have been very disappointed right it's in the shop for a slew of things....makes me sick!!!!
Porter

Little Rock, AR

#4 May 7, 2007
I have a 2001 PT. I am trying to relplace the generator and I can not remove the lower control arm from the steering knuckle. HELP!
melissa

United States

#5 Mar 18, 2008
where is the right wheel bearing located on a 2001 pt cruiser
Deb

Wyandotte, OK

#6 Mar 22, 2008
2005 PT Convertible Turbo...had to have the alternator replaced at 36,500 miles. To the total cost of 800 bucks...OUT of warranty. Not in the least bit happy, especially when I had to replace hubs and bearings on the front wheels at 44,000 miles. The wheel bearings are in the hub... you'll need to pull the hub and take it to a machine shop to have them press out the old bearing, and press the new ones in. Cost: 500 bucks for both sides, including new hubs.
Eric

Saint Paul, MN

#7 Apr 16, 2008
This is a nice vintage car..if only Chrysler made it with less problems people would've bought them like candies. Never buying Chrysler again. Only bought it because I wanted to support the union workers of America.
Phil

Sterling Heights, MI

#8 Apr 24, 2008
Eric wrote:
Only bought it because I wanted to support the union workers of America.
Eric,
Only problem is: The PT Cruiser is not made by union workers in America........

It's made in Toluca, Mexico. Those workers there make about $2 to $3 an hour; so they can't even afford the product they build!
Phil
Lenora

Hicksville, NY

#9 May 11, 2008
My 2001 PT Cruiser battery light on the console started coming on yesterday. I took it to a shop and they tested the batery and said I need a new alternator. They quoted me 150.00 for a new alternator, but they don't do the repair work. The shop next door will do the work for 160.00. Now I find out that I might need a belt as well, but the repair shop or the shop that tested the battery said anything about that. Where can I find a honest repair shop they would not look at me as just a women and try to cheat me?

I'm in the Bronx, NY
Anthony

Holland, MI

#10 May 17, 2008
trying to change alternator on 2001 pt cruiser..how do i get the axle out
Kim

Boynton Beach, FL

#11 Jun 26, 2008
I have had the same thing happen in my (used) PT Cruiser since I have owned it in Feb. My husband has been saiying the alternator needed replacing and had even bought the belt. Today it completely died on me while I was on the road. It has been towed to a local repair shop. My husband normally handles all car things, but is out of the country. How much is too much to fix this? I have no idea and would hate to get taken for too much..
Lenora wrote:
My 2001 PT Cruiser battery light on the console started coming on yesterday. I took it to a shop and they tested the batery and said I need a new alternator. They quoted me 150.00 for a new alternator, but they don't do the repair work. The shop next door will do the work for 160.00. Now I find out that I might need a belt as well, but the repair shop or the shop that tested the battery said anything about that. Where can I find a honest repair shop they would not look at me as just a women and try to cheat me?
I'm in the Bronx, NY
frank

United States

#12 Jul 11, 2008
is the 02 and 03 pt cruiser alternator removed the same way
tracy

United States

#13 Aug 29, 2008
our pt has been a very big pain this year. we just got it out of the shop a week ago, and now it is either the battery or alternator which we do not have the money for. Is there any easy way to tell which it is, it is died in the drive way????? help please.....
cheryl

Springfield, IL

#15 Oct 6, 2008
2005 pt turbo conv -- need help/tips on replacing battery cables to starter..first attempt at car repair (in over my head?!) stopped for gas yesterday and car would not turn over, power everywhere, but engine does nothing, tried different key still nothing. Been reading online sounds like typical for cables to go bad to starter..got it to start by disconnecting and reconnecting cable on battery post, but only gets me one start.(where is starter located in relation to battery?) Would like to be able to handle some of this smaller stuff myself, willing to learn, but don't want to hurt car (or me)..
hillbilly678

United States

#16 Nov 5, 2009
Larry Adams wrote:
Can anyone tell me what you must do to change a alternator on a 2002 PT Cruiser 4 cyl. Thanks Larry
ok larry heres how its the easiest way ur not gonna believe this where the exhaust manifold is there is an ear sticking out where part of the heat shield is bolted on the corner u do not need that corner so cutt it off with a small grinder or zip wheel and after u have removed the heat shield ull know how much to cut off on the corner this is the only thing holding it back from coming out i just did one 10 min ago my alternator is out in less than 10 min dont do all that other stuff cause theres a lot more to do with what there telling u to do
hillbilly678

United States

#18 Nov 5, 2009
Anthony wrote:
trying to change alternator on 2001 pt cruiser..how do i get the axle out
anthony see my detailed instruction on changing that alternator hillbilly678
sickofPT

Williamsburg, VA

#20 Dec 23, 2009
I've finally had it with this POS. IT's been nothing but trouble, considering howlittle it's been driven.. Wish I could pull it up in front of the dealers and set it on fire.
maggie

Pictou, Canada

#21 Jan 4, 2010
Are u using the term generator and alternator as one and the same??
Whitey wrote:
The PT utilizes a generator. I would recommend that you use a service guide if you attempt this procedure. It contains numerous illustrations and instructions for the sub procedures mentioned below.
Generator
Removal - 2.4L Turbo
The generator is located above the oil filter and axle shaft.
1. Disconnect the negative battery cable.
2. Remove the 2 bolts from the top of the heat shield on the generator.
3. Remove nut from the upper T-bolt adjustment bracket.
4. Raise vehicle and support.
5. Remove the right front wheel.
6. Remove the accessory drive splash shield.
7. Remove the lower heat shield bolt.
8. Remove the generator heat shield.
9. Unplug the field circuit from the generator.
10. Remove the B+ terminal nut and wire.
11. Loosen the accessory drive belt t-bolt.
12. Remove the pencil strut.
13. Loosen the lower generator pivot bolt.
14. Remove the generator belt, refer to the Cooling section for more information.
15. Remove the axle retaining nut.
16. Remove the lower control arm from the steering knuckle.
17. Remove the 2 bolts for the axle shaft bearing support.
18. Remove the axle shaft assembly. Put a container under the transmission to catch the transmission fluid from the transmission.
19. Remove the generator from the lower mounting bracket and set generator to the side.
20 . Remove the lower mounting bracket for the generator.
21. Remove generator through the axle shaft hole.
Installation - 2.4L Turbo
1. Install generator through the axle shaft hole in wheel well.
2. Put generator on upper t-bolt and loosen install the nut.
3. Install the lower mounting bracket for the generator to the block and tighten bolts to 54 N-m or 40 ft./lbs.
4. Loose install the lower pivot bolt for the generator.
5. Install the B+ terminal nut and wire and tighten nut to 11.3 N-m or 100 in./lbs.
6. Plug in the field circuit to the generator.
7. Install the axle shaft assembly.
8. Install the 2 bolts for the axle shaft bearing support and tighten bolts to 54.2 N-m or 40 ft./lbs.
9. Install the axle shaft into the steering knuckle.
10. Install the lower control arm to the steering knuckle and install the bolt and tighten bolts to 94.9 N-m or 70 ft./lbs.
11. Install the axle retaining nut and tighten nut to 244 N-m or 180 ft./lbs.
12. Install and tension the generator belt, refer to the Cooling section for more information.
13. Tighten the accessory drive belt t-bolt and tighten nut to 54 N-m or 40 ft./lbs.
14. Tighten the lower generator pivot bolt and tighten bolts to 54 N-m or 40 ft./lbs.
15. Install the pencil strut.
16. Install the generator heat shield.
17. Install the lower heat shield bolt and tighten bolt to 54.2 N-m or 40 ft./lbs.
18. Install the accessory drive splash shield.
19. Install the right front wheel.
20. Lower vehicle.
21. Tighten nut to the upper adjustment bracket and tighten to 25 N-m or 18 ft./ lbs.
22. Install the 2 bolts to the heat shield on the generator and tighten bolts to 4.5 N-m or 40 in./lbs.
23. Connect the negative battery cable.
Rick

Saint Clair Shores, MI

#22 Aug 22, 2010
How do I replace the lower control arm rear bolt retaining nut?
DPHB

Pearland, TX

#23 Aug 22, 2010
Rick wrote:
How do I replace the lower control arm rear bolt retaining nut?
Get a cutting torch.....

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