AR15.40-P-5032SN | Remove and install alternator | 22.11.02 |
ENGINE 660.940 in MODEL 450.3 /4 (except , 450.418)
P43.05-2022-04
1 Clips
2 Belt cover
P15.40-2203-09
3 Connector
4 Nut
5 Electrical connection
6 Bolt
11 Torque wrench
12 Gauge (V-belt tension)
G2 Alternator
7 Lock nut
8 Bracket
9 Adjusting screw
10 Poly-V-belt
| Remove | ||
1 | Disconnect battery ground cable | ||
2 | Lower rear drive module | ||
3 | Pull out the spreader pin on the clip (1) and remove the belt cover (2) | ||
4 | Remove the alternator cover | Model 450.3 up to 14.11.99 | |
Model 450.3 as of 15.11.99, 450.4 | |||
Pay attention to the connector assignment, see: | |||
Alternator connector assignment | |||
5 | Pull out the plug (3) on the alternator (G2) | Do not damage the latching lugs, otherwise the plug (3) will not lock anymore. | |
6 | Unscrew the nut (4) on the alternator (G2) and pull out the electrical connector (5) upwards | ||
7 | Unscrew the bolt (6) for the alternator (G2) on the assembly carrier, counter nut (7) for the alternator (G2) on the holder (8) and remove the adjusting screw (9) | Box wrench | |
Joint socket wrench bit | |||
8 | Remove poly-V-belt (10) | ||
9 | Remove alternator (G2) | ||
| Install | ||
10 | Check the poly-V-belt (10) for wear or damage and replace if necessary | On vehicles with AC system Plus Code I01 or AC system Plus (with combination filter and outside temperature display) smart&passion Code I29 the poly-V-belt supercharger must be removed to replace the poly-V-belt (10). See: | |
Remove poly V-belt of supercharger | |||
11 | Install alternator (G2) | ||
12 | Insert the bolt (6) for the alternator (G2) on the assembly carrier and screw in down to the support | Do not tighten the bolt (6) fully. | |
13 | Insert the adjusting screw (9) and screw in the counter nut (7) for the alternator (G2) on holder (8) down to the support | Do not tighten the adjusting screw (9) and counter nut (7) fully. | |
14 | Insert the electrical connector (5) from above and screw the nut (4) firmly onto the alternator (G2) | | |
15 | Place the plug (3) on the alternator (G2) | Do not damage the latching lugs, otherwise the plug (3) will not lock anymore. | |
Pay attention to latching of plug (3). | |||
16 | Fit on poly V-belt (10) | ||
17 | Apply tension to the poly-V-belt (10) via the adjusting screw (9) at the alternator (G2) | The alternator (G2) must be easy to swivel before tensioning begins. | |
18 | Tighten the counter nut (7) for the alternator (G2) on the holder (8) | The poly-V-belt (10) must be tensioned via the adjusting screw (9) using the torque wrench (11) | |
| |||
Box wrench | |||
Joint socket wrench bit | |||
19 | Tighten the bolt (6) for the alternator (G2) on the assembly carrier | | |
Box wrench | |||
Joint socket wrench bit | |||
| Check | ||
20 | Crank the engine 3 times by hand and check the pretension of the poly-V-belt (10) | Use the measuring instrument (V-belt tension) (12) at the area shown only. Turn the engine further by hand and check a number of times. Adjustment value for initial assembly of poly-V-belt: 450 N. Adjustment value for repeat installation of poly-V-belt: 410 N. | |
Gauge (V-belt tension) | |||
21 | Install the alternator cover | Model 450.3 up to 14.11.99 | |
Model 450.3 as of 15.11.99, 450.4 | |||
Pay attention to the connector assignment, see: | |||
Alternator connector assignment | |||
22 | Install the belt cover (2) and fix in place with clips (1) | ||
23 | Position rear drive module | ||
24 | Connect ground cable to battery | ||
25 | Undertake a function test for "battery charging" | ||
| Connect STAR DIAGNOSIS and read out fault memory | ||
STAR DIAGNOSIS diagnosis system |
Belt tensioning device
Number | Designation | Engine | |
BA13.25-P-1001-01J | Nut at adjusting screw alternator | Nm | 27.5 |
BA13.25-P-1002-01J | Bolt of alternator to major assembly carrier | Nm | 27.5 |
Alternator
450 589 04 21 00
Gauge (V-belt tension)
Ring wrench
Joint socket wrench bit
450 589 06 09 00
450 589 00 21 00
Commercially available tools