Remove/install alternator

AR15.40-P-5032GA

Remove/install alternator

14.2.12

 

Remove/install

1.1

Activate Service mode in Tele-Aid emergency call system

 Only for code ET2: TELE AID - car telephone emergency call system.

AR82.95-P-0005-03GR



Notes regarding the Tele-Aid emergency call system

AH82.95-P-0001-01GA

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

2

Disconnect battery ground line

AR54.10-P-0003G



Notes on battery

All models

AH54.10-P-0001-01A

Danger!

Risk of death caused by vehicle slipping or toppling off the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

3

Lift/jack up vehicle

AR00.60-P-1000G

4

Remove underride guard

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.

Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.

Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

5

Drain coolant



Replace coolant

AP20.00-P-2080G



Notes on coolant

All engines

AH20.00-N-2080-01A

6

Remove air filter (1)

AR09.10-P-1050GD

7

Remove air intake hose (2)

 Detach connection of wheelhousing liner.

Installation: Align air intake hose (2) free of tension at air filter connection.

8

Remove cover (3)

9

Remove fan shroud

AR20.40-P-6800GD

10

Remove radiator

AR20.20-P-3865GM

11

Remove intercooler

AR09.41-P-6817GA

12

Remove coolant hoses (4) in front of alternator (G2) to facilitate access

13

Remove poly-V belt

AR13.22-P-1202GD

14

Remove bolt (5) of coolant line fixture

15

Remove bolt (6) of dipstick guide tube and remove guide tube

 Installation: Ensure that the guide pipe is seated correctly.

16

Disconnect electrical connection (7)

17

Expose nut for terminal B+ to alternator (8) and remove electrical line



*BA15.40-P-1002-01D

18

Remove bolt (9) for electric cable fixture

19

Remove bracket (10) of control unit. Remove bolts (11) of bracket and remove bracket

20

Remove bolts (12) of cooler housing (13)



*BA15.40-P-1006-01D

21

Push alternator (G2) complete with cooler housing (13) to the right and take it out to the front

 Installation: Attach cooler housing (13) and alternator (G2) each with new O-ring at crankcase and cooler housing (13).

22

Install in the reverse order

23

Pour in coolant



Replace coolant

AP20.00-P-2080G



Notes on coolant

All engines

AH20.00-N-2080-01A

24

Inspect cooling system for leaks



Cooling and heating system - Check condition of radiator, lines and hoses

AP20.00-P-2050G

25

Carry out functional test

26

Render electrical system operational

 Carry out basic programming (normalize windows and sliding roof, etc.).

27.1

Deactivate service mode in TELE AID emergency call system

 Only for code ET2: TELE AID - car telephone emergency call system.

AR82.95-P-0005-03GR



Notes regarding the Tele-Aid emergency call system

AH82.95-P-0001-01GA

28

Read out fault memory and erase

 STAR DIAGNOSIS
Stored faults which can result from lines being disconnected or from simulation during removal and installation or test work, have to be processed and erased in the fault memories after completing the work



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS Compact diagnosis system for passenger cars

Number

Designation

Engine
628

BA15.40-P-1002-01D

Nut, circuit B+ to alternator

Nm

14

BA15.40-P-1006-01D

Bolt, alternator cooler housing to crankcase

M7

Nm

-

M8

Nm

20