Remove and installing the alternator

AR15.40-W-5032B

Remove and installing the alternator

14.2.12

19.3.04

Work procedure reworked.

Steps 4 to 13

 

Removal/installation

1

Switch off ignition

 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 cable of battery



Notes on the battery

AH54.10-P-0001-01A

3

Remove bottom noise encapsulation

 Danger!

Risk of injury caused by pinching or jamming when working on loaded springs or spring bodies

Use only approved clamping devices; shield off hazard area if necessary.
Inspect special tools for damage and proper operation (visual inspection).
Wear protective gloves.

AS00.00-Z-0001-01A

4

Release the tension on poly-V-belt and remove the belt pulley (4) on the alternator (G2)

 Installation: Check condition of poly-V-belt and replace if necessary

Observe poly-V-belt routing plan.

AR13.22-W-3902-02A



Damage patterns of poly-V-belt

AP13.22-D-1351-01A

5

Remove cable tie and take cover (1) off the alternator (G2)

6

Remove tie straps and take off electrical wiring harness (2) on bracket (5)

7

Remove electrical wiring harness (2) on alternator (G2)



*BA15.40-N-1003-01C



*BA15.40-N-1004-01C



*BA15.40-N-1010-01C



*BA15.40-N-1011-01C

8

Remove alternator (G2) on carrier (3) and take out in a downward direction

 A spacer washer is installed for some alternators (G2); observe the installation position of this spacer washer.

 Installation: Check belt pulley (4) and fan wheel for alternator (G2) for damage and smooth running,

9

Replace belt pulley (4) and fan wheel. Counterhold the generator shaft with a socket wrench to do this.



*BA15.40-N-1002-01C

Push bushing (3.1) back into carrier (3) and insert alternator (G2).



*BA15.40-N-1001-01C

10

Install in reverse order

11

Synchronize tachograph

12

Set clock

13

Enter radio code

Number

Designation

Engines
541.9, 542.9
through to end no.
177213

BA15.40-N-1001-01C

Bolt/nut for alternator on carrier

M10

Nm

50

M12

Nm

80

BA15.40-N-1002-01C

Nut for belt pulley on generator

M161.5

Nm

80

BA15.40-N-1003-01C

Nut for electrical line on terminal B+ for alternator

Nm

8

BA15.40-N-1004-01C

Nut for electrical line on terminal B for alternator

Nm

6

BA15.40-N-1010-01C

Nut for electrical line on terminal W for alternator

Nm

4

BA15.40-N-1011-01C

Nut for electrical line on terminal D+ for alternator

Nm

2