Remove/install starter-alternator

AR15.40-P-6000MCC

Remove/install starter-alternator

28.4.15

Engine

132.910 in model 451.334/380/480

Modification notes

21.12.12

Measure falling away of the axial bearing play of the starter-alternator in an installed condition.

Shown on vehicle with an old bearing design

1

Electrical connection

4

Screw/bolt (old bearing design up to 17.04.11)

7

Poly-V belt

2

Electrical connection

5

Belt tensioner

M1/10

Starter-alternator

3

Pin

6

Screw/bolt

Shown on vehicle with an old bearing design

5

Belt tensioner

8

Screw/bolt

9

Bushing (old bearing design up to production date 17.04.11)

M1/10

Starter-alternator

The bearing design as of manufacture date 18.04.11 or vehicles up to manufacture date 17.04.11 for which after 18.04.11 as new starter-alternator (M1/10) was installed with a new bearing design was installed (picture A) Repair solution for bearing damage for vehicles up to manufacture date 17.04.11 without exchange of the starter-alternator (M1/10) (picture B)

10

Timing case cover

14

Collared bushing inside with cone

11

Bearing housing (screw/bolt)

15

Collared bushing inside

12

Bearing housing (nut with a cone)

16

Collared bushing outside with inside thread

13

Collared bushing outside

17

Bearing housing (screw/bolt)



Remove

1

Disconnect ground line of battery

AR54.10-P-0003MCC

2

Lower rear drive module

AR01.00-P-3050MCC

3

Remove fender liner in right fender

AR88.10-P-1400MCC

4

Remove poly-V belt (7) of the starter-alternator (M1/10)

Engine 132.910 in model 451.334/380/480 up to 8/30/10

AR13.22-P-0005MCC

Engine 132.910 in model 451.334/380/480 as of 8/31/10

AR13.22-P-0005MCB

5.1

Remove screw/bolt (4) on the starter-alternator (M1/10)

Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles with the old bearing design.

5.2

Remove bearing housing (17) from the rear on starter-alternator (M1/10)

Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles on which an old bearing design was already replaced by the new bearing design.

 For vehicles for which the old bearing design was already replaced by the new bearing design, the threaded connection takes place through the bearing liner (17) from the rear. The associated collared bushing is glued in on the outside with inside thread (16) in the timing case cover (10).

5.3

Remove bearing housing (11) on starter-alternator (M1/10) and remove bearing housing (12)

Engine 132.910 in model 451.334/380/480 as of 4/18/11
Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles on which, after 18.04.11, a new starter-alternator (M1/10) with a new bearing design was installed.

6

Remove screw/bolt (6) for the belt tensioner (5) on the timing case cover (10)

7

Lower vehicle with vehicle lift

8

Disconnect electrical connections (1, 2) at the starter-alternator (M1/10)

9

Unscrew nut at the stud (3) and remove the three-phase line at the starter-alternator (M1/10)

10

Take out the starter-alternator (M1/10) upwards

11

Remove screw/bolt (8) and remove the belt tensioner (5) from the starter-alternator (M1/10)

When replacing the starter-alternator (M1/10).

12.1

Remove bushing (9) from timing case cover (10)

Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles with an old bearing design when the bushing (9) should be replaced by the new bearing design due to bearing damage or the starter-alternator (M1/10) must be exchanged.

 There are two bearing bushings (9) in the timing case cover (10).

12.2

Remove collared bushing on the outside with inside thread (16) and the collared bushing on the inside (15) from the timing case cover (10) (picture B)

Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles for which the old bearing design was already replaced by the new bearing design without exchanging the starter-alternator (M1/10).

12.3

Remove collared bushing on the outside (13) and the collared bushing on the inside with cone (14) from the timing case cover (10) (picture A)

Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles with the old bearing design.
When replacing the starter-alternator (M1/10).

13

Raise vehicle with vehicle lift

Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles with the old bearing design.

14

Remove guide bearing for the starter-alternator (M1/10) from the timing case cover (10)

 Use a 16 mm split pin punch (see specific tooling for engines).

Vehicles up to 17.04.11 where the old bearing design is replaced by the new bearing design due to bearing damage or the starter-alternator (M1/10) is exchanged:



Remove starter-alternator guide bearing

AR15.40-P-6000-02MCC

 Internal extractor

*000589253300

 Extraction tool

*221589043300

 Impact extractor

*602589003300

Vehicles up to 17.04.11, for modification to the new bearing design due to bearing damage, without exchange of the starter-alternator (M1/10):



Remove starter-alternator guide bearing

AR15.40-P-6000-02MCD

 Extraction tool

*451589014300

Vehicles as of 18.04.11:



Remove starter-alternator guide bearing

AR15.40-P-6000-02MCE

 Extraction tool

*451589014300



Install

15

Install pilot bushing on starter-alternator (M1/10)

Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles with the old bearing design.
For modification of the old bearing design to the new bearing design due to bearing damage, without exchange of the starter-alternator (M1/10).

AR15.40-P-6000-03MCC

Starter-alternator thrust bearing play repair solution

*BE15.40-P-1001-03A

 Drilling fixture

*451589002300

16.1

Insert collared bushing on the inside (15) in the timing case cover (10) and glue collared bushing on the outside with inside thread (16) in the timing case cover (10) (picture B)

Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles with the old bearing design.
For modification of the old bearing design to the new bearing design due to bearing damage, without exchange of the starter-alternator (M1/10).

 The collared bushing on the outside with inside thread (16) must always be inserted from the front in the timing case cover (10) and glued in with the bearing securing device (picture B).

Mounting adhesive, Loctite 648

*BR00.45-Z-1010-02A

16.2

Insert collared bushing on the outside (13) and the collared bushing on the inside with cone (14) into the timing case cover (10) (picture A)

Engine 132.910 in model 451.334/380/480
When replacing the starter-alternator (M1/10).

 The collared bushing on the inside with cone (14) must always be inserted from the rear in the timing case cover (10). It serves to guide the bearing housing (12) (picture A).

17

Place belt tensioner (5) on starter-alternator (M1/10) and tighten with screw/bolt (8)

When replacing the starter-alternator (M1/10).

 Bolt, belt tensioner to starter/alternator

*BA13.25-P-1002-01V

18

Lower vehicle with vehicle lift

Engine 132.910 in model 451.334/380/480 up to 4/17/11M1Vehicles with an old bearing design when the old bearing design were replaced by the new bearing design due to bearing damage or the starter-alternator (/10) is exchanged.

19

Position starter-alternator (M1/10) on installation location

20

Raise vehicle with vehicle lift

21.1

Remove bearing housing (17) from the rear on starter-alternator (M1/10)

Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles on which an old bearing design was already replaced by the new bearing design.

 For vehicles for which the old bearing design was already replaced by the new bearing design, the threaded connection takes place through the bearing housing (17) from the rear. The associated collared bushing is glued in on the outside with inside thread (16) in the timing case cover (10).

 Screw/bolt, alternator to timing case cover

*BA15.40-P-1008-01G

21.2

Put bearing housing (12) in place and tighten down with bearing housing (11) on the starter-alternator (M1/10)

Engine 132.910 in model 451.334/380/480 as of 4/18/11
Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles on which, after 18.04.11, a new starter-alternator (M1/10) with a new bearing design was installed.

 Screw/bolt, alternator to timing case cover

*BA15.40-P-1008-01G

22

Insert the cover from the scope of supply from outside instead of the screw/bolt (4) on the starter-alternator (M1/10)

Engine 132.910 in model 451.334/380/480 up to 4/17/11Vehicles for which the new bearing design without exchange of the starter-alternator (M1/10) were already implemented.

23

Lower vehicle with vehicle lift

24

Place three-phase line on starter-alternator (M1/10) and tighten with the nut on pin (3)

 Nut, three-phase line to starter/alternator

*BA15.40-P-1009-01G

25

Attach electrical connections (1, 2) to the starter-alternator (M1/10)

26

Place screw/bolt (6) for belt tensioner (5) on timing case cover (10)

 The screw/bolt (6) is fully tightened only at the time of installing the poly-V belt (7).

27

Install poly-V belt (7) for starter-alternator (M1/10)

Engine 132.910 in model 451.334/380/480 up to 8/30/10

AR13.22-P-0005MCC

Engine 132.910 in model 451.334/380/480 as of 8/31/10

AR13.22-P-0005MCB

 Tighten screw/bolt (6) for belt tensioner (5).

 Bolt, belt tensioner to timing case cover

*BA13.25-P-1001-01V

28

Install fender liner in right fender

AR88.10-P-1400MCC

29

Position rear drive module

AR01.00-P-3050MCC

30

Connect ground line to battery

AR54.10-P-0003MCC

Check values for starter-alternator bearing play

Number

Designation

Engine 132.910 in model 451.334/380/480

BE15.40-P-1001-03A

Starter-alternator thrust bearing play repair solution

Minimum

mm

0,1

Maximum

mm

0,5

 Belt tensioning device

Number

Designation

Engine 132.910 in model 451.334/380/480

BA13.25-P-1001-01V

Bolt, belt tensioner to timing case cover

Nm

45

 Belt tensioning device

Number

Designation

Engine 132.910 in model 451.334/380/480

BA13.25-P-1002-01V

Bolt, belt tensioner to starter/alternator

Nm

28

 Alternator

Number

Designation

Engine 132.910 in model 451.334/380/480

BA15.40-P-1008-01G

Screw/bolt, alternator to timing case cover

Nm

23

 Alternator

Number

Designation

Engine 132.910 in model 451.334/380/480

BA15.40-P-1009-01G

Nut, three-phase line to starter/alternator

Nm

17

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-02A

Mounting adhesive, Loctite 648

A 003 989 32 71 10