Remove/install alternator

AR15.40-P-5032PD

Remove/install alternator

14.2.12

 

Remove/install

 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

1

Disconnect battery ground line

 Only Model 203: Do not connect quiescent current retention unit.

Model 203

AR54.10-P-0003P

Model 209

AR54.10-P-0003Q



Notes on battery

All models

AH54.10-P-0001-01A

2

Remove cylinder head cover trim

Engine 611

Engine 612

AR01.20-P-5014-02B



*BA01.20-P-1002-01A



*BA01.20-P-1003-01A

3

Remove poly-V belt

AR13.22-P-1202HB

4

Remove intake air scoop (1)

5

Remove air intake hose (2)

6

Disconnect charge air hose (3) from charge air pipe (4)

7

Remove bolts (5)



*001589760900

8

Remove charge air pipe (4)

9

Remove bottom section of soundproofing

AR94.30-P-5300P

 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

10

Drain coolant

11

Remove torsion bar on front axle

 Installation: Do not use grease or antifriction agent.

AR32.20-P-0300P

12

Disconnect electric cable circuit 30 (6)



*BA15.40-P-1002-01D

13

Disconnect electric cable circuit 61 (7)

14

Remove bolts (9)



*001589760900

15

Place high pressure line of steering (8) to the side

16

Remove bolts (11)



*001589760900

17

Remove bracket (10)

18

Remove bolts (12)



*BA15.40-P-1001-01D



*001589760900

19

Take alternator (G2) down and out

 Installation: Insert new seal between cooling housing flange and engine housing to avoid leaks.

 Installation: Replace O-ring (14) for coolant feed line (13) to avoid leaks.

20

Install in the reverse order

21

Render electrical system operational

See: 

Perform basic programming.

Model 203

AR00.19-P-0200P

Model 209

AR00.19-P-0200Q

Number

Designation

Engine 612.961/
962/967

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
611, 612

BA15.40-P-1001-01D

Bolt, alternator to timing case cover

Nm

20

BA15.40-P-1002-01D

Nut of circuit B+ to alternator

Nm

18