Remove/install alternator

AR15.40-P-5032PM

Remove/install alternator

14.2.12

 

Remove/install

 Danger!

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

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the 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 attach quiescent current retention unit otherwise a short circuit can occur.

Model 203

AR54.10-P-0003P

Model 209

AR54.10-P-0003Q



Notes on battery

AH54.10-P-0001-01A

2

Remove cylinder head cover trim

AR01.20-P-5014-02A

3

Remove air filter housing

AR09.10-P-1150PM

4

Remove poly-V belt

AR13.22-P-1202PM

5

Remove front soundproofing bottom section

AR94.30-P-5300P

6

Disconnect charge air hose (1) on charge air duct (6)

 Installation: Check sealing rings for damages and replace if necessary. Ensure exact mounting of safety clip in order to avoid leaks.

 Oil traces and low oil quantities in charge air hose (1) come from crankcase ventilation and are permissible.

7

Remove charge air duct (6) on turbocharger and alternator (G2)

To do this, remove bolts (5).

8

Disconnect electric cable circuit 30 (2)



*BA15.40-P-1002-01D

9

Disconnect electric cable circuit 61 (3)

10

Remove bolts (4)



*BA15.40-P-1001-01D

11

Take alternator (G2) down and out

12

Install in the reverse order

13

Perform basic programming

Model 203

AR00.19-P-0200P

Model 209

AR00.19-P-0200Q

14

Read out fault memory and erase

 Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

15

Carry out function check

Number

Designation

Engines
646, 647.961, 648

BA15.40-P-1001-01D

Bolt, alternator to timing case cover

Nm

20

BA15.40-P-1002-01D

Nut of circuit B+ to generator

Nm

18