Remove/install alternator

AR15.40-P-5032GS

Remove/install alternator

14.2.12

14.8.03

Value changed from 22 Nm to 9 Nm

Value in BA09.40-P-1005-01C modified for engine 612.965/966

*BA09.40-P-1005-01C

 

Remove/install



Notes regarding the Tele-Aid emergency call system

 Only with code ET2.

AH82.95-P-0001-01GA

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

 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



Notes on battery

All models

AH54.10-P-0001-01A

2

Connect no load current retention unit

AR54.10-P-1030-07I

Quiescent current retention unit

3

Disconnect ground cable from battery

AR54.10-P-0003G

Danger!

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

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

AS00.00-Z-0010-01A

4

Lift/jack up vehicle

AR00.60-P-1000G

5

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

6

Drain coolant

AP20.00-P-2080G

7

Remove cylinder head cover trim

AR01.20-P-5014-02B



*BA01.20-P-1002-01A



*BA01.20-P-1003-01A

8

Remove air filter

AR09.10-P-1050GI

9

Remove poly-V belt

AR13.22-P-1202HB

10

Remove charge air pipe

AR09.41-P-1311GS

11

Separate coupling (1) for circuit 61

12

Disconnect electric cable circuit 30 (2)

13

Remove bolt (3) of bracket

14

Remove oil feed line (5) at crankcase and at turbocharger

  To do this unscrew bolt (4).

*BA09.40-P-1004-01C

  Installation: Install new gaskets.

*BA09.40-P-1005-01C

15

Remove coolant feed line (6)

 Installation: Install new gaskets.

16

Remove bolt (7) for bracket

17

Remove bolts (8) for alternator (G2)



*BA15.40-P-1007-01E

18

Remove alternator (G2) downwards

 Installation: Insert new gasket between cooling housing flange and engine housing.

19

Install in the reverse sequence

20

Inspect oil level, adjust to correct level if necessary

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

21

Check for oil leaks with engine running

22.1

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

23

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 612.965

BA01.20-P-1002-01A

Bolt, trim panel of cylinder head cover to cylinder head cover

Nm

10

BA01.20-P-1003-01A

Bolt, charge air distribution pipe cover to charge air manifold

Nm

10

Number

Designation

Engine 612.965/
966

BA09.40-P-1004-01C

Oil feed line to turbocharger

Screw socket

Nm

30

Banjo bolt

Nm

-

BA09.40-P-1005-01C

Bolt, oil feed line to cylinder head

Nm

9

Number

Designation

Engine
612.965/
966 with 12V alternator

BA15.40-P-1007-01E

Bolt, cooler housing of alternator to crankcase

Nm

20