Remove/install alternator

AR15.40-P-5032QB

Remove/install alternator

14.2.12

 

Remove/install

 Danger!

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof.

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0011-01A

1

Open engine hood

Model 203

AR88.40-P-1000P

Model 209

AR88.40-P-1000Q

 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 ground line from battery

 Insulate ground line clamp as a protection against unintentional contact of dismounted ground line with ground point of battery.



Notes on battery

AH54.10-P-0001-01A

Model 203

AR54.10-P-0003P

Model 209

AR54.10-P-0003Q

3

Remove front engine cover (7)

 Pull out front engine cover (7) from mounts.

4

Remove right intake air duct (8)

5

Remove fan shroud

Engine 273

AR20.40-P-5000QB

6

Remove poly-V-belt

AR13.22-P-1202QB

7

Remove bracket for front engine cover (9) and place with air pump switchover valve (Y32) aside

Model 203

 Do not detach lines at air pump switchover valve (Y32).



*BA01.30-P-1009-01O

8

Remove electric air pump (M33)

Model 203.087 /092 /287 /292

AR14.30-P-7251QB

9

Remove aspirator shutoff valve (10) at right cylinder head

Model 203, 209 with engine 273

AR14.30-P-7200QB

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

10

Raise vehicle with lifting platform

AR00.60-P-1000P

11

Dismount lower engine compartment paneling

AR61.20-P-1105P

12

Remove cap (1) and disconnect tml. 30 electrical line (B+) (3) from alternator (G2) by unscrewing nut (2).



*BA15.40-P-1002-01F

13

Disconnect plug for electrical line for circuit 61 (D+) (4) from alternator (G2)

14

Remove lower bolts (5) from alternator (G2)



*BA15.40-P-1001-01F

15

Lower vehicle with lifting platform

AR00.60-P-1000P

16

Remove upper bolts (6) from alternator (G2)



*BA15.40-P-1001-01F

17

Take alternator (G2) down and out

18

Install in the reverse order

Number

Designation

Engine
272

Engine
273

BA15.40-P-1001-01F

Bolt connecting alternator to timing case

Nm

20

20

BA15.40-P-1002-01F

Nut of circuit B+ to alternator

Nm

15

15

Number

Designation

Engine
272

Engine
273

BA01.30-P-1009-01O

Bolt, switchover valve bracket to cylinder head

M6

Nm

9

9