Remove/install alternator

AR15.40-P-5032MFF

Remove/install alternator

16.01.2020

Engine

654 in model 118, 177, 247

Modification notes

14.10.2019

Screw, alternator to major assembly carrier/oil filter

BA15.40-P-1004-01Q

15.01.2020

Document completely revised.

14.10.2019

Bolt, alternator to major assembly carrier/crankcase

AR15.40-P-0002-01MFA

BA15.40-P-1001-01V

14.10.2019

Screw, alternator to major assembly carrier/oil filter

AR15.40-P-0002-01MFA

BA15.40-P-1004-01Q

1

Air intake line

2

Charge air hose

8

Coolant line

9

Vent line

10

Nut

11

Refrigerant line

12

Refrigerant line

13

Refrigerant line

14

Longitudinal member

3

Cap

6

Electrical connector

4

Nut

7

Bolts

5

Electrical line B+

G2

Alternator

7

Bolts

G2

Alternator

7

Bolts

G2

Alternator

 Danger

Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained.

AS83.00-Z-0001-01A

 Danger

Risk of fire due to ignition of R1234yf refrigerant on hot components. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with escaped R1234yf refrigerant and when working on pressurized parts. Risk of explosion due to formation of ignitable refrigerant/air mixtures

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0007-01A

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A



Remove

1

Remove upper engine cover.

AR01.10-P-2405MFF

2

Disconnect ground line of on-board electrical system battery (G1).

AR54.10-P-0003MFA

3

Discharge air conditioning system.

AR83.30-P-1760MFA

4

Remove air intake line (1).

5

Remove charge air hose (2).

AR09.41-P-1311-01AL

6

Seal openings using protective cover.

 Set of protective caps

*001589029100

7

Remove fan unit.

AR20.40-P-5050MFF

8

Drain off coolant.

AR20.00-P-1142MFF

9

Remove poly-V-belt.

AR13.22-P-1202MFF

10

Lower vehicle.

AR00.60-P-1006A

11

Remove coolant line (8).

AR20.20-P-7441-01RQ

12

Seal openings using protective cover.

 Set of protective caps

*001589009100

13

Remove bleed line(9).

AR20.20-P-7441-01RQ

14

Seal openings with suitable stop plug.

 Record plug

*129589009100

15

Remove nut (10).

16

Remove refrigerant line (11) from refrigerant line (12).

17

Place refrigerant line (11) to one side and fix in place with cable tie.

18

Remove sealing ring from refrigerant line (11).

 Assembly tool

*000589936300

19

Seal openings with suitable stop plug.

 Record plug

*129589009100

20

Remove refrigerant line (13) from longitudinal member (14).

 Clip remover

*452589016300

21

Release front module until alternator (G2) can be removed.

Engine 654 in model 247.6 (except 247.651), 247.7 (except 247.751/753/754)

AR88.30-P-1064MFX

Engine 654 in model 118, 177, 247.0

AR88.30-P-1064MFA

22

Protect adjacent component parts in the working area from damage using suitable means.

23

Remove cover (3).

24

Remove nut (4).

25

Remove electric line B+ (5) from alternator (G2) and place to one side.


Do not kink, crush or subject electric line B+ (5) to tension.
Otherwise damage will occur.

26

Release and disconnect electrical connector (6).

27

Release lower bolt (7).

28

Unscrew upper bolt (7) and remove as shown.

29

Pull alternator (G2) forward in direction of arrow (A).

30

Slightly tighten upper bolt (7) again by hand.

 Remove alternator (G2) together with bolts (7).

31

Turn alternator (G2) in the direction of the arrow (B).

 The belt pulley of the alternator (G2) must point in the direction of the oil filter housing.

32

Turn alternator (G2) in direction of arrow (C).

33

Remove alternator (G2) upwards as shown in direction of arrow (D).



Install

34

Install alternator (G2) as shown in opposite direction to arrow (D).

35

Turn alternator (G2) in opposite direction to arrow (C).

36

Turn alternator (G2) in opposite direction to arrow (B).

37

Unscrew upper bolts (7) and remove as shown.

38

Install alternator (G2) in opposite direction to arrow (A) and position on major assembly carrier.

39

Tighten screws (7) slightly by hand.

40

Tighten bolts (7).

Tighten alternator screws/bolts

AR15.40-P-0002-01MFA

 Screw, alternator to major assembly carrier/oil filter

*BA15.40-P-1004-01Q

41

Connect and lock electrical connector (6).

42

Attach electric line B+ (5) to alternator (G2).

43

Attach nut (4).

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 Nut, circuit B+ to alternator

*BA15.40-P-1001-01Q

44

Install cover (3).

45

Remove suitable means from adjacent component parts in working area.

46

Install poly-V-belt.

AR13.22-P-1202MFF

47

Secure front module.

Engine 654 in model 247.6 (except 247.651), 247.7 (except 247.751/753/754)

AR88.30-P-1064MFX

Engine 654 in model 118, 177, 247.0

AR88.30-P-1064MFA

48

Attach refrigerant line (13) to longitudinal member (14).

49

Remove appropriate stop plugs.

 Record plug

*129589009100

50

Attach sealing ring to refrigerant line (11).

 Replace sealing ring.

 Assembly tool

*000589936300

51

Remove cable tie from refrigerant line (11).

52

Attach refrigerant line (11) to refrigerant line (12).

53

Attach nut (10).

 Nut, refrigerant line connecting point

*BA83.30-P-1002-01T

54

Remove appropriate stop plugs.

 Record plug

*129589009100

55

Install bleed line (9).

AR20.20-P-7441-01RQ

56

Remove protective covers.

 Set of protective caps

*001589009100

57

Install coolant line (8).

AR20.20-P-7441-01RQ

58

Install fan unit.

AR20.40-P-5050MFF

59

Remove protective covers.

 Set of protective caps

*001589029100

60

Install charge air hose (2).

AR09.41-P-1311-01AL

61

Install air intake line (1).

62

Attach ground line of the on-board electrical system battery (G1).

AR54.10-P-0003MFA

63

Fill air conditioning.

AR83.30-P-1760MFA

64

Fill in coolant.

AR20.00-P-1142MFF

65

Install upper engine cover.

AR01.10-P-2405MFF



Check

 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

66

Perform engine test run and check alternator (G2) for proper operation.

 Alternator

Number

Designation

Engine 654 in model 118, 177, 247

BA15.40-P-1001-01Q

Nut, circuit B+ to alternator

Nm

17

 Alternator

Number

Designation

Engine 654 in model 118, 177, 247

BA15.40-P-1004-01Q

Screw, alternator to major assembly carrier/oil filter

Stage 1

Nm

8

Stage 2

Nm

20

 Air conditioning

Number

Designation

Model 118

Model 177

BA83.30-P-1002-01T

Nut, refrigerant line connecting point

M6

Nm

12

12

M8

Nm

20

20

 Air conditioning

Number

Designation

Model 247

BA83.30-P-1002-01T

Nut, refrigerant line connecting point

M6

Nm

12

M8

Nm

20