Alternator: Service and Repair

WM 272219 Removing and installing the generator

Tools





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 air box for throttle housing (intake manifold). => 243519 Removing and installing air box for throttle housing (intake manifold) - section on "Removing"
3. Remove air cleaner housing lid. => 242455 Replacing air-cleaner element
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. Remove belt tensioner. => 137319 Removing and installing belt tensioner - section on "Removing"

Removing the generator





Overview of generator

1. Release connector -1- ( -arrow A- ) and pull it off -arrow B-.





Loosening electric connections on the generator

2. Screw off fastening nut -2- and pull off the B+ line -3- ( -arrow C- ).
3. Unscrew fastening screws -3- and remove the generator to the side -arrow-. Press generator out of the bracket using a lever if necessary.





Removing generator

4. Release supply and return hose -2- on the generator -3-.





Releasing supply and return hose on the generator

4.1. Clamp the two hoses -2- using the hose clamp 3094.
4.2. Press spring band clamps -1- together and pull supply and return hose -2- off the water hose adapters on the generator -3-.
5. Lift generator up and out. Press the upper cooling water hose aside if necessary.

Installing the generator

1. Secure supply and return hose -2- on the generator -3-.





Securing supply and return hose on the generator

1.1. Slide new spring band clamp -1- onto the supply and return hose -2-.
Grease supply and return hose -2- on the inside with Vaseline.

Information

- Before installing the new generator, tap the threaded bushings -d- out by approx. 4 mm -arrows-.





Threaded bushing on generator

1.2. Insert the generator -3- from above.
1.3. Press spring band clamps -1- together and slide supply and return hose -2- onto the water hose adapters on the generator -3- ( -arrow- ).
2. Loosen the hose clamp 3094 on the water hoses and remove it.
3. Place the generator in installation position -arrow- and secure with the fastening screws -arrows 3-. => Tightening torque: 20 Nm (15 ftlb.)





Securing the generator

4. Connect the B+ line -3- to the generator -arrow A- and secure with the fastening nut -2-. => Tightening torque: 15 Nm (11 ftlb.)





Securing electric connections on the generator

5. Press in connector -1- ( -arrow B- ) until it engages securely.

Subsequent work

1. Install belt tensioner. => 137319 Removing and installing belt tensioner - section on "Installing"
2. Install air cleaner housing lid. => 242455 Replacing air-cleaner element
3. Install air box for throttle housing (intake manifold). => 243519 Removing and installing air box for throttle housing (intake manifold) - section on "Installing"
4. Connect the battery and carry out the work instructions. => 90 Work instructions after disconnecting the battery
5. Fit engine guard. => 108019 Removing and installing engine guard - section on "Installing"