Remove/install alternator

AR15.40-P-5032TA

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 ground line from battery

 Insulate ground line to prevent unintentional contact between the detached ground line and battery ground point.

Model 211.0

AR54.10-P-0003T

Model 211.2

AR54.10-P-0003TA



Notes on battery

AH54.10-P-0001-01A

2

Trim panels of cylinder head cover

remove

AR01.20-P-5014-02C

 Bolt, cylinder head cover trim to cylinder head

*BA01.20-P-1002-01G

 Bolt, cover to charge air manifold

*BA01.20-P-1003-01G

3

Remove fan shroud

AR20.40-P-6800T

4

Remove poly-V belt

AR13.22-P-1202T

5

Remove bottom section of soundproofing at front

AR94.30-P-5300T

6

Remove charge air hose upstream of charge air cooler

 Traces and small quantities of oil entering the charge air hose from the crankcase ventilation are permissible.

 Installation: Inspect seals for damage and replace if required. Ensure the safety clamps are exactly installed.

7

Detach electrical line of circuit 30 (2) on alternator (G2)

 Nut, circuit B+ to alternator

*BA15.40-P-1002-01D

8

Disconnect electrical line of circuit 61 (3) at alternator (G2)

9

Detach bracket (1) from oil pan

 so that the alternator can be (G2) removed.

 Bolt connecting oil cooler line to engine oil pan

*BA27.55-P-1003-01B

10

Disconnect hydraulic lines (5) for the automatic transmission

 Shim receptacle and close of lines with  stop plugs.

 So that the alternator can be (G2) removed.

 Line connections at double hose clamp

*BA27.55-P-1005-01B

 Set of plugs

*129589009100

11

Remove bolts (4)

 Bolt, alternator to timing case cover

*BA15.40-P-1001-01D

12

Take alternator (G2) down and out

13

Install in the reverse order

14

Check oil level in automatic transmission, correct if necessary

AR27.00-P-0100AC

15

Carry out function check

16.1

Check sensor setting of Distronic

Vehicles with Distronic, code 219a

AR30.30-P-1000R

Number

Designation

Engine
648

BA01.20-P-1002-01G

Bolt, cylinder head cover trim to cylinder head

Nm

9

BA01.20-P-1003-01G

Bolt, cover to charge air manifold.

Nm

9

Number

Designation

Engine
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

Number

Designation

Trans-mission 722.6 in model 211

BA27.55-P-1003-01B

Bolt, oil cooler line to engine oil pan

Nm

11

BA27.55-P-1005-01B

Line connectors to dual clamp

Nm

25