Alternator: Service and Repair
WM 272219 Removing and installing generator
Technical values
Preliminary work
Preliminary work for removing and installing generator
1. Disconnect the battery. -> 2X00IN Work instructions after disconnecting the battery 2X00IN Work instructions after disconnecting the battery
2. Remove right wheel housing liner. -> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair
3. Remove right air cleaner housing. -> 242519 Removing and installing air cleaner housing - section on "Removing" Service and Repair
4. Remove engine guard. -> 108019 Removing and installing engine guard - section on "Removing" 108019 Removing and installing engine guard
5. Drain coolant. -> 193817 Draining and filling coolant (includes bleeding) - section on "Draining" Service and Repair
6. Release drive belt. -> 137819 Removing and installing drive belt - section on "Removing" Service and Repair
7. Remove cooling fan housing (radiator frame). -> 19201903 Removing and installing cooling fan housing (radiator frame) - section on "Removing" Service and Repair
Removing 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).
Information
- The pictures shown in this document may differ from the original.
- However, this does not affect the validity and relevance of the pictures.
Installation position of generator
1. Vehicles with turbocharger:
Release hose connections on the turbocharger. To do this, pull out the locking spring -1- on the adapter for the pressure pipe for the turbocharger. Then loosen the hose clamp -2- on the pressure pipe at the turbocharger.
Releasing hose connection on turbocharger
2. Vehicles with turbocharger:
Pull off the pressure pipe and intake pipe on the turbocharger.
3. Vehicles with turbocharger:
Disconnect the connection at the charge-air cooler. To do this, remove the locking clip -1- and pull off the line. Disconnect line -2- for the ambient air valve. To do this, remove the spring band clamp and pull off the line.
Disconnecting connection on charge-air cooler
4. Vehicles with turbocharger:
Remove clamp -1- on the ambient air valve and pull off the hose -2- ( -A- ). Lift charge air hose -3- up and remove it -B-.
Removing charge air hose
5. Vehicles with turbocharger:
Pull off vacuum supply hose -1- at the ambient air valve -2-.
Vacuum hose on ambient air valve
6. Loosen clamp -1- on the coolant hose -2- at the top of the coolant pump connection piece.
Pull off the hose and push it to one side.
Right coolant hose
7. Loosen ground strap on generator.
Loosening ground strap
7.1. Unscrew fastening screw -1-.
7.2. Remove ground strap -2- from the generator -arrow-.
8. Remove impact bracket. => Removing impact bracket
Removing impact bracket
8.1. Unclip coolant return hose -1- at the impact bracket -2- ( -A- ).
8.2. Unclip electric line -3- at the impact bracket -2- ( -B- ).
8.3. Unscrew fastening screws -4- and remove impact bracket -2- ( -C- ).
9. Unclip line -1- at the generator -arrow-.
Unclipping line on generator
10. Unclip coolant return hose -1- from the holder -2-.
Release clamp -3- on the coolant return hose -1- at the generator and pull off return hose.
Coolant return hose
11. Release clamp -1- on the coolant supply hose -2- and pull off the coolant supply hose.
Coolant supply hose
12. Remove holder for generator lines.
Removing holder for generator lines
12.1. Unclip electric lines for the generator and oxygen sensor at the holder -1- ( -arrows A- ).
12.2. Unscrew fastening screw -2-.
12.3. Open the retaining clip -3- ( -arrow B- ) and remove the B+ line -4- ( -arrow C- ).
12.4. Slide the holder -1- aside -arrow D- and leave it hanging in the vehicle.
13. Disconnect plug connection for generator.
Disconnecting plug connection for generator
13.1. Release plug connection for the generator -1- ( -arrow A- ) and disconnect it -arrow B-.
13.2. Pull plug connection for the generator -1- along with the line bracket off the B+ line -arrow C-.
14. Remove clamp -1- and pull the coolant hose -2- off the coolant pipe.
Disconnecting coolant hose
15. Unscrew the three fastening screws -1 and 2- ( -arrows- ) and support the generator with your hand.
Unscrewing fastening screws on generator
16. Pull the generator forward.
17. Take the holder => Removing holder for generator lines for the oxygen sensor line and generator line out of the vehicle.
18. Disconnect B+ line at the generator.
Disconnecting B+ line at the generator
18.1. Screw off fastening nut -1-.
18.2. Remove B+ line -2- from the generator -arrow-.
19. Remove the generator -1- from the vehicle.
Removing generator
19.1. Protect the radiator and cylinder head from damage by covering them with a piece of cardboard, for example.
19.2. Move the generator -1- forward and lift it up out of the vehicle -arrow-.
Installing generator
Information
- The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.
1. Protect the radiator and cylinder head from damage by covering them with a piece of cardboard, for example.
Fit the generator -1- down into the vehicle from the front -arrow- and position it.
Installing generator
2. Secure B+ line to generator.
Securing B+ line to generator
2.1. Position the B+ line -2- on the generator -arrow-.
2.2. Tighten the fastening nut -1-. => Tightening torque: 15 Nm (11 ftlb.)
3. Fit the holder for the generator lines and oxygen sensor line into the vehicle and position it. => Installing holder for generator lines
4. Fit and tighten the three fastening screws -1, 2- ( -arrows- ). => Tightening torque: 23 Nm (17 ftlb.)
Tightening fastening screws for generator
5. Slide the coolant hose -2- onto the coolant pipe -arrow- and fit the clamp -1-.
Securing coolant hose
6. Connect plug connection for generator.
Connecting plug connection for generator
6.1. Clip in plug connection for generator -1- together with the line bracket on the B+ line -A-.
6.2. Connect plug connection for the generator -1- ( -B- ) until the generator plug connection engages securely.
7. Install holder for generator lines.
Installing holder for generator lines
7.1. Position the holder -1- ( -A- ).
7.2. Insert B+ line -4- into the retaining clip -3- ( -B- ) and close the retaining clip -C-.
7.3. Tighten the fastening screw -2-. => Tightening torque: 10 Nm (7.5 ftlb.)
7.4. Clip in electric lines for the generator and oxygen sensor at the holder -1- ( -D- ).
8. Connect the coolant supply hose -2- and fit the clamp -1-.
Coolant supply hose
9. Connect the coolant return hose -1- and fit the clamp -3-.
Coolant return hose
10. Clip coolant return hose -1- into the holder -2-.
11. Clip in line -1- on the generator -arrow-.
Clipping in line on generator
12. Install impact bracket.
Installing impact bracket
12.1. Position impact bracket -2- ( -A- ) and secure with the fastening screws -4-. => Tightening torque: 10 Nm (7.5 ftlb.).
12.2. Clip in electric line -3- at the impact bracket -B-.
12.3. Clip in coolant return hose -1- at the impact bracket -C-.
13. Secure ground strap on the generator.
Securing ground strap on generator
13.1. Position ground strap -2- on the generator -arrow-.
13.2. Tighten fastening screw -1-. => Tightening torque: 20 Nm (15 ftlb.).
14. Connect the coolant hose -2- at the top to the connection piece and fit the clamp -1-.
Top right coolant hose
15. Vehicles with turbocharger:
Connect vacuum supply hose -1- at the ambient air valve -2-.
Vacuum hose on ambient air valve
16. Vehicles with turbocharger:
Insert charge air hose -3- from above -A-. Slide the hose -2- onto the ambient air valve -B- and fit the spring band clamp -1-.
Installing charge air hose
17. Vehicles with turbocharger:
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 connection on charge-air cooler
18. Vehicles with turbocharger:
Secure the hose connection to the turbocharger. To do this, connect the intake pipe and tighten the hose clamp -2-. 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 turbocharger
Subsequent work
Subsequent work for removing and installing generator
1. Install cooling fan housing (radiator frame). -> 19201903 Removing and installing cooling fan housing (radiator frame) - section on "Installing" Service and Repair
2. Fit drive belt. -> 137819 Removing and installing drive belt - section on "Installing" Service and Repair
3. Install right air cleaner housing. -> 242519 Removing and installing air cleaner housing - section on "Installing" Service and Repair
4. Install wheel housing liner at the right. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair
5. Install engine guard. -> 108019 Removing and installing engine guard - section on "Installing" 108019 Removing and installing engine guard
6. Connect the battery. -> 2X00IN Work instructions after disconnecting the battery 2X00IN Work instructions after disconnecting the battery
7. Check and top up coolant. -> 193817 Draining and filling coolant (includes bleeding) - section on "Filling" Service and Repair