Remove/install alternator

AR15.40-P-5032PF

Remove/install alternator

14.2.12

 

Remove/install

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

 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

 Do not connect quiescent current retention unit.

AR54.10-P-0003P



Notes on battery

All models

AH54.10-P-0001-01A

2

Remove poly-V belt

 Only detach from alternator.

AR13.22-P-1202HB

3

Remove engine compartment paneling

AR61.20-P-1105P

4

Detach coupling for headlamp range adjustment

5

Detach headlamp range adjustment sensor (3) from body

 Remove nuts (2) and protect sensor against damage.

6

Unscrew stabilizer bar on front axle

 Pull off rubber mount, check and replace if necessary. Do not use grease or antifriction agent so as not to damage the rubber mount.



*BA32.20-P-1003-02B

7

Swivel torsion bar downwards

8

Unscrew bracket (1) on automatic lines

 Push automatic line to one side since this simplifies removal and installation.

9

Detach electrical line for circuit B+



*BA15.40-P-1002-01D

10

Detach electrical line for circuit D+



*BA15.40-P-1003-01D

11

Remove bolts (4)



*BA15.40-P-1001-01D

12

Take alternator (G2) down and out

13

Install in the reverse order

14

Render electrical system operational

See: 

Perform basic programming.

AR00.19-P-0200P

15

Read out fault memory and erase

Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

Number

Designation

Engine
611, 612

BA15.40-P-1001-01D

Bolt, alternator to timing case cover

Nm

20

BA15.40-P-1002-01D

Nut, circuit B+ to alternator

Nm

18

BA15.40-P-1003-01D

Nut, circuit D+ to alternator

Nm

5

Number

Designation

Model 203
except
model
203.020/220/
08/09/28/29

BA32.20-P-1003-02B

Self-locking nut, torsion bar bracket to front axle carrier

Nm

40