Remove/install alternator

AR15.40-W-5032NB

Remove/install alternator

26.06.2020

Engine

934.9 in model 967

Shown on alternator from Remy

1

Belt pulley

4

Electrical connector

7

Screw

2

Electrical connection (only for code D6F (A/C))

5

Ground cable

8

Screw

3

Refrigerant compressor (only for code D6F (Air conditioning system))

6

Electrical line

G2

Alternator

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Warning

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension

Use only approved tensioning devices; additionally screen off hazardous area if necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves.

AS00.00-Z-0001-01A

 Warning

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A



Remove

1

Switch off ignition.

2

Tilt cab.

3

Remove soundproofing.

4

Disconnect ground line on battery.

AR54.10-W-0003NA

5

Remove left charge air pipe at engine, place towards front and attach to cooler unit.

AR09.41-W-1327NA

 Do not remove charge air pipe on the left from black charge air hose.

6

Slacken poly-V-belt and remove from the belt pulley (1) of the alternator (G2).

AR13.22-W-3902-05MD

7

Expose electrical connector (2) on ground line (5).

Only for vehicles with code D6F (Air conditioning).

8

Disconnect electrical connector (2) of refrigerant compressor (3).

Only for vehicles with code D6F (Air conditioning).

9

Release electrical connector (4) and disconnect at alternator (G2).

10

Remove screw of ground line (5) at alternator (G2).

11

Remove screws (7) of alternator (G2).

 For vehicles with alternators (G2) from the company Bosch only 2 screw/bolts (7) are installed.

12

Loosen screw (8) of the alternator (G2).

13

Remove nut of electric line (6) at terminal B+ of alternator (G2).

 To do this slightly tip the alternator (G2).

14

Remove screw (8) and remove alternator (G2).



Check

15

Check belt pulley (1) of the alternator (G2) for damage and smooth operation.

 If damage is present on the alternator belt pulley (1), replace the alternator (G2).



Install

16

Attach alternator (G2) with screw (8) to the crankcase.

 Screw in screw (8) to just before end stop, but do not yet tighten.

17

Attach electric line (6) to the circuit B+ of the alternator (G2).

 To do this slightly tip the alternator (G2).

 Nut, electrical line to alternator terminal B+

*BA15.40-N-1004-01U

18

Screw in screws (7) of alternator (G2) and tighten screws (7, 8).

 Only tighten down upper screw/bolt (7) with bracket after installation of the charge air pipe on the left.

 Bolt, alternator to crankcase

*BA15.40-N-1001-01U

19

Attach ground line (5) to alternator (G2).

 Bolt, ground line to alternator

*BA15.40-N-1005-01U

20

Connect electrical connector (4) to alternator (G2).

21

Connect electrical connector (2) of refrigerant compressor (3).

Only for vehicles with code D6F (Air conditioning).

22

Fix electrical connection (2) with cable ties to ground line (5).

Only for vehicles with code D6F (Air conditioning).

23

Mount poly-V-belt on belt pulley (1) of alternator (G2) and tension.

AR13.22-W-3902-05MD

Belt drive routing diagram

AR13.20-W-1000-01MD



Damage profiles for a poly-V belt

AP13.22-D-1351-01A

 Check condition of poly-V-belt, replace if necessary.

24

Attach left charge air pipe.

AR09.41-W-1327NA

25

Tighten top screw (7) of alternator (G2).

 Bolt, alternator to crankcase

*BA15.40-N-1001-01U

26

Connect ground line to battery.

AR54.10-W-0003NA

27

Start engine and perform an engine test run.

28

Check left charge air pipe for leak tightness and switch off engine.

29

Install soundproofing.

30

Tilt back cab.

 Alternator

Number

Designation

Engine 934.9

BA15.40-N-1001-01U

Bolt, alternator to crankcase

Nm

50

 Alternator

Number

Designation

Engine 934.9

BA15.40-N-1004-01U

Nut, electrical line to alternator terminal B+

M8

Nm

15

 Alternator

Number

Designation

Engine 934.9

BA15.40-N-1005-01U

Bolt, ground line to alternator

M6

Nm

6