Alternator: Service and Repair

WM 272219 Removing and installing the generator

Technical values





Preliminary work

1. Before the generator can be removed, the battery must be disconnected and the terminal covered. => 90 Work instructions after disconnecting the battery
2. Remove right wheel housing liner. => 505619 Removing and installing front wheel housing liner - section on "Removing"
3. Remove right air cleaner housing. => 242519 Removing and installing air cleaner housing - section on "Removing"
4. Remove engine guard. => 108019 Removing and installing engine guard - section on "Removing"
5. Drain coolant. => 193817 Draining and filling in coolant (includes bleeding) - section on "Draining"
6. Detach lock carrier and move it to the service position. => 503809 Detaching and fastening lock carrier (service position) - section on "Detaching"
7. Remove drive belt. => 137819 Removing and installing drive belt - section on "Removing"

Removing the generator

Information

- When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high pressure blast is not directed directly onto the three-phase generator (risk of bearing damage).





Installation position of generator

1. Loosen hose connection on the turbocharger. To do this, pull out the locking spring -1- on the turbocharger adapter. Then loosen the hose clamp -2- on the pressure pipe on the turbocharger.





Releasing hose connection on the turbocharger

2. Disconnect the connection on the charge air cooler. To do this, remove the locking clip -1- and pull off the line. Disconnect line -2- of the ambient air valve. To do this, remove the spring band clamp and pull off the line.





Disconnecting the connection on the charge air cooler

3. Release connector -1- on the mass air flow meter -arrow A- and pull it off -arrow B-.





Pulling off connector on mass air flow meter

4. Remove spring band clamp -1- from ambient air valve and pull off hose -2- ( -arrow A- ). Lift charge air hose -3- up and remove it -arrow B-.





Removing charge air hose

5. Pull hose line -arrow- off the vacuum unit for the bypass valve. Where hose is tight, carefully lever off with a screwdriver.





Removing hose from the vacuum unit of the bypass valve

6. Loosen ground strap on generator.
6.1. Unscrew fastening screw -1-.
6.2. Remove ground strap -2- from generator -arrow-.





Loosening ground strap

7. Remove impact bracket.
7.1. Unclip return coolant hose -1- at the impact bracket -2- ( -arrow A- ).
7.2. Unclip electric line -3- at the impact bracket -2- ( -arrow B- ).
7.3. Unscrew fastening screws -4- and remove impact bracket -2- ( -arrow C- ).





Removing impact bracket

8. Seal the coolant hoses -1 and 2- with a hose clamp -3- to prevent them from leaking.





Sealing coolant hoses with hose clamp

9. Unclip line -1- on generator -arrow-.





Unclipping line on generator

10. Loosen supply connection piece on generator.
10.1. Unscrew fastening screw -2- on the supply connection piece -1-.
10.2. Remove supply connection piece -1- from the generator -arrow-.





Removing supply connection piece on generator

11. Remove heat shield for generator lines.
11.1. Unclip electric lines for the generator and oxygen sensor at the heat shield -1- ( -arrows A- ).
11.2. Unscrew fastening screw -2-.
11.3. Open the retaining clip -3- ( -arrow B- ) and remove the B+ line -4- ( -arrow C- ).
11.4. Lift heat shield -1- up and remove it -arrow D-.





Removing heat shield for generator lines

12. Disconnect plug connection for generator.
12.1. Release plug connection for generator -1- ( -arrow A- ) and disconnect it -arrow B-.
12.2. Pull off plug connection for generator -1- and the line bracket from the B+ line -arrow C-.





Disconnecting plug connection for generator

13. Remove spring band clamp -1- and pull off coolant hose -2- from the coolant pipe.





Undoing coolant hose

14. Unscrew the three fastening screws -1 and 2- ( -arrows- ) and support the generator with your hand.





Unscrewing fastening screws on generator

15. Remove return connection piece on generator.
15.1. Unscrew fastening screw -1- on the return connection piece.
15.2. Remove return connection piece -2- from the generator -arrow A-.
15.3. Swivel the generator -3- out -arrow B- until the B+ line is accessible.





Removing return connection piece on generator

16. Remove B+ line on the generator.
16.1. Screw off fastening nut -1-.
16.2. Remove B+ line -2- from the generator -arrow-.





Removing B+ line on generator

17. Remove generator -1- through the opening in the wheel housing -arrow-.





Removing the generator

Installing the generator

1. Insert the generator -1- through the opening in the wheel housing and position it on the engine -arrow-.





Installing the generator

2. Secure B+ line to generator.
2.1. Position B+ line -2- on generator -arrow-.
2.2. Tighten fastening nut -1-. => Tightening torque: 15 Nm (11 ftlb.)





Securing B+ line to generator

3. Secure return connection piece on generator.
3.1. Swivel generator -3- in -arrow A- until the connection piece for the return line -2- can be installed.
3.2. Grease the new seal on the return connection piece -2- with Vaseline.
3.3. Press return connection piece -2- as far as it will go into the return coolant bore on the generator -arrow B- and secure with the new fastening screw -1-. => Tightening torque: 10 Nm (7.5 ftlb.)





Securing return connection piece on generator

4. Position the three fastening screws -1 and 2- ( -arrows- ) and tighten them. => Tightening torque: 23 Nm (17 ftlb.)





Tightening fastening screws on generator

5. Push coolant hose -2- onto the coolant pipe -arrow- and fit the spring band clamp -1-.





Securing coolant hose

6. Connect plug connection for generator.
6.1. Clip in plug connection for generator -1- and the line bracket on the B+ line -arrow A-.
6.2. Connect plug connection for the generator -1- ( -arrow B- ) until the generator plug connection -1- engages securely.





Connecting plug connection for generator

7. Install heat shield for generator lines.
7.1. Insert heat shield -1- from above and position it -arrow A-.
7.2. Insert B+ line -4- into the retaining clip -3- ( -arrow B- ) and close the retaining clip -3- ( -arrow C- ).
7.3. Tighten fastening screw -2-. => Tightening torque: 10 Nm (7.5 ftlb.)
7.4. Clip in electric lines for the generator and oxygen sensor at the heat shield -1- ( -arrows D- ).





Installing heat shield for generator lines

8. Secure supply connection piece on generator.
8.1. Grease the new seal on the supply connection piece -1- with Vaseline.
8.2. Press supply connection piece -1- as far as it will go into the supply coolant bore on the generator -arrow- and secure with the new fastening screw -2-. => Tightening torque: 10 Nm (7.5 ftlb.)





Securing supply connection piece on generator

9. Clip in line -1- on generator -arrow-.





Clipping in line on generator

10. Remove hose clamps -3- on the coolant hoses -1 and 2-.





Removing hose clamps on coolant hoses

11. Install impact bracket.
11.1. Position impact bracket -2- ( -arrow A- ) and secure with fastening screws -4-. => Tightening torque: 10 Nm (7.5 ftlb.).
11.2. Clip in electric line -3- at the impact bracket -2- ( -arrow B- ).
11.3. Clip in return coolant hose -1- at the impact bracket -2- ( -arrow C- ).





Installing impact bracket

12. Secure ground strap on generator.
12.1. Position ground strap -2- on generator -arrow-.
12.2. Tighten fastening screw -1-. => Tightening torque: 20 Nm (15 ftlb.).





Securing ground strap on generator

13. Attach hose line -arrow- to the vacuum unit of the bypass valve.





Attaching hose to the vacuum unit of the bypass valve

14. Insert the charge air hose -3- from above -arrow A-. Push hose -2- onto the ambient air valve -arrow B- and fit the spring band clamp -1-.





Installing charge air hose

15. Connect connector -1- onto the mass air flow meter ( -arrow- ) until the connector -1- engages securely.





Connecting connector onto mass air flow meter

16. Connect the hose line to the charge air cooler. Ensure that the locking clip -1- is fitted correctly. Then connect the line to the ambient air valve -2- and fit the spring band clamp.





Connecting the connection on the charge air cooler

17. Connect hose to the turbocharger. To do this, connect the pressure pipe -2- and tighten the hose clamp. Then fit the line from the charge air cooler. The connection piece must engage audibly. Ensure that the sheetmetal clip -1- is fitted correctly.





Securing hose connection to the turbocharger

Subsequent work

1. Install drive belt. => 137819 Removing and installing drive belt - section on "Installing"
2. Fill in coolant. => 193817 Draining and filling in coolant (includes bleeding) - section on "Filling in"
3. Fasten lock carrier. => 503809 Detaching and fastening lock carrier (service position) - section on "Fastening"
4. Install right air cleaner housing. => 242519 Removing and installing air cleaner housing - section on "Installing"
5. Install right wheel housing liner. => 505619 Removing and installing front wheel housing liner - section on "Installing"
6. Fit right front wheel. => 440519 Removing and installing wheel - section on "Installing"
7. Connect the battery and carry out the work instructions. => 90 Work instructions after disconnecting the battery
8. Fit engine guard. => 108019 Removing and installing engine guard - section on "Installing"