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. 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. Remove heat shield on generator.
1.1. Undo the two fastening screws -1-.
1.2. Unclip heat shield -2- at the retaining clip -arrow A- and remove it in an upward direction -arrow B-.





Removing heat shield on generator

2. Undo heat shield at the exhaust manifold.
2.1. Undo the two fastening screws -1-.
2.2. Unclip heat shield -2- at the three retaining clips -arrows A- and push it back out of the working area -arrow B-.





Releasing heat shield at exhaust manifold

3. Loosen ground strap on generator.
3.1. Unscrew fastening screw -1-.
3.2. Remove ground strap -2- from generator -arrow-.





Loosening ground strap

4. Remove impact bracket.
4.1. Unclip return coolant hose -1- at the impact bracket -2- ( -arrow A- ).
4.2. Unclip electric line -3- at the impact bracket -2- ( -arrow B- ).
4.3. Unscrew the three fastening screws -4- and remove the impact bracket -2- ( -arrow C- ).





Removing impact bracket

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





Sealing coolant hoses with hose clamp

6. Loosen supply connection piece on generator.
6.1. Unscrew fastening screw -2- on the supply connection piece -1-.
6.2. Remove supply connection piece -1- from the generator -arrow-.





Removing supply connection piece on generator

7. Remove heat shield for generator lines.
7.1. Unclip electric lines for the generator and oxygen sensor at the heat shield -1- ( -arrows A- ).
7.2. Unscrew fastening screw -2-.
7.3. Open the retaining clip -3- ( -arrow B- ) and remove the B+ line -4- ( -arrow C- ).
7.4. Lift heat shield -1- up and remove it -arrow D-.





Removing heat shield for generator lines

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





Disconnecting plug connection for generator

9. Remove coolant pipe on the engine.
9.1. Unscrew fastening screw -1-.
9.2. Route coolant pipe -2- down out of the working area -arrow-.





Removing coolant pipe on the engine

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





Unscrewing fastening screws on generator

11. Remove return connection piece on generator.
11.1. Unscrew fastening screw -1- on the return connection piece.
11.2. Remove return connection piece -2- from the generator -arrow A-.
11.3. Swivel the generator -3- out -arrow B- until the B+ line is accessible.





Removing return connection piece on generator

12. Remove B+ line on the generator.
12.1. Screw off fastening nut -1-.
12.2. Remove B+ line -2- from the generator -arrow-.





Removing B+ line on generator

13. Remove generator -1- through the opening - wheel housing liner with air-cleaner box removed -arrow-.





Removing the generator

Installing the generator

1. Insert the generator -1- through the opening - wheel-housing liner with air-cleaner box removed - 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. Secure coolant pipe on the engine.
5.1. Position coolant pipe -2- on the engine -arrow-.
5.2. Tighten fastening screws -1-. => Tightening torque: 10 Nm (7.5 ftlb.)





Securing coolant pipe on engine

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 it engages securely -1-.





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





Removing hose clamps on coolant hoses

Information

As of calendar week 42/2008, some screws on the engine were changed to aluminium screws.

The impact bracket for the generator has been secured with aluminium screws since then.

Observe specifications in the document => 1001IN IMPORTANT component changes for V8 engines as of October 2008.

10. Install impact bracket.
10.1. Position impact bracket -2- ( -arrow A- ) and secure with three fastening screws -4-.=> Tightening torque: 10 Nm (7.5 ftlb.).
=> Initial tightening: 10 Nm (7.5 ftlb.) and => Final tightening: 90°
10.2. Clip in electric line -3- at the impact bracket -2- ( -arrow B- ).
10.3. Clip in return coolant hose -1- at the impact bracket -2- ( -arrow C- ).





Installing impact bracket

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





Securing ground strap on generator

12. Secure heat shield on exhaust manifold.
12.1. Position heat shield -2- ( -arrow A- ) and clip it in at the three retaining clips -arrows B-.
12.2. Tighten both fastening screws -1-. => Tightening torque: 10 Nm (7.5 ftlb.)





Securing heat shield on exhaust manifold

13. Install heat shield on generator.
13.1. Insert heat shield -2- from above -arrow A- and clip it in with the retaining clips -arrow B-.
13.2. Tighten both fastening screws -1-. => Tightening torque: 10 Nm (7.5 ftlb.)





Installing heat shield on generator

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"
3. Install right air cleaner housing. => 242519 Removing and installing air cleaner housing - section on "Installing"
4. Install right wheel housing liner. => 505619 Removing and installing front wheel housing liner - section on "Installing"
5. Connect the battery and carry out the work instructions. => 90 Work instructions after disconnecting the battery
6. Fit engine guard. => 108019 Removing and installing engine guard - section on "Installing"