Chrysler Repair: rear valve cover removal on 1994 3.0L Plymouth Voyager, alternator pulley, alternator belt


Question
I am using an Haynes repair manual to help in replacing the valve cover gaskets.  the front went ok, but the rear will not clear the alternator for removal.  the manual does not mention this problem.  it does say to removethe plenum but i hesitate to without some other guidance as it seems unnecessary. can you help?

Answer
Hi George,
My '94 manual doesn't make any remarks about that problem. But it looks to me that removing the alternator should not be a problem. You can remove the belt from it by releasing the tension on the belt by rotating the spring loaded tensioner clockwise. To do that notice there is a 1/2" square hole in the tensioner assembly and if you put a 1/2"  breaker bar or torque wrench or ratchet handle in the hole that gives you the lever to rotate it in order to relieve the tension on the alternator belt for removal. The tensioner is behind the idler pulley, sort of midway between the alternator and the power steering pump.
Then you just have to remove the two bolts that hold the alternator to its bracket. When you reassemble, the larger bolt is torqued to 30 foot pounds, and the smaller one to 21 foot pounds. Rotate the tensioner clockwise again to allow the belt to go back on the alternator pulley. Before you take the belt off notice how it is threaded around the various components in case it slips off one of them. I personally don't have the 3.0 engine so I have to admit I'm suggesting this based on what I see in the manual.

Roland