Remove/install alternator

AR15.40-P-5032GL

Remove/install alternator

14.2.12

14.8.03

Value changed from 22 Nm to 9 Nm

Value in BA09.40-P-1005-01C modified for engine 612.965/966

*BA09.40-P-1005-01C

 

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 cable from battery

AR54.10-P-0003GL



Notes on battery

All models

AH54.10-P-0001-01A

2

Remove air filter

AR09.10-P-1050GI

3

Remove charge air cooler

AR09.41-P-6817GT

4

Remove poly-V belt

AR13.22-P-1202HB

5

Remove charge air pipe

AR09.41-P-1311GS

6

Remove coolant hose

 To do this remove clamp (3).

7

Remove alternator 24 V (G2/1)

AR15.40-P-5032GX

8

Separate clutch circuit 61 (1)

9

Unclamp electrical line for circuit B+ (2)

 Installation: For model 461.331 seal connection for electrical line for circuit B+ (2).

*BR00.45-Z-1070-01A



*BA15.40-P-1001-01E

10

Remove mounting clamps of the electrical lines at alternator (G2)

 Installation: Check protective hose (11) for electrical lines for damage; replace if necessary

11

Remove oil feed line (5) at crankcase and turbocharger

For this step, unscrew bolt (4).

 Installation: Replace the gaskets.



*BA09.40-P-1004-01C



*BA09.40-P-1005-01C

12

Remove coolant feed line (6)

13

Remove bolt (7) on bracket

14

Slacken top bolt at bracket

 The bracket must be swiveled a little to the side for better accessibility to bolt (10).

15

Remove bolts (8, 9, 10)

 Collect escaping coolant in a suitable vessel.



*BA15.40-P-1007-01E

16

Take out alternator (G2) towards the front

 Installation: Insert new gasket between cooling housing flange and engine housing.

17

Install in the reverse sequence

18

Read out fault memory and erase

 STAR DIAGNOSIS
Stored faults which can result from lines being disconnected or from simulation during removal and installation or test work have to be processed and erased in the fault memories after completing the work



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS Compact diagnosis system for passenger cars

Number

Designation

Engine 612.965/
966

BA09.40-P-1004-01C

Oil feed line to turbocharger

Screw socket

Nm

30

Banjo bolt

Nm

-

BA09.40-P-1005-01C

Bolt, oil feed line to cylinder head

Nm

9

Number

Designation

Engine
612.965/
966 with 12V alternator

Engine
612.966 with 24V alternator

BA15.40-P-1001-01E

Nut, circuit B+ to alternator

Nm

14

18

BA15.40-P-1007-01E

Bolt, cooler housing of alternator to crankcase

Nm

20

-

Number

Designation

Order number

BR00.45-Z-1070-01A

Scotch Seal 5300 sealant, gray

-