Alternator: Service and Repair
WM 272219 Removing and installing generator
Technical values
Preliminary work
1. Disconnect the battery. -> 2X00IN Work instructions after disconnecting the battery 2X00IN Work instructions after disconnecting the battery.
2. Remove right front wheel -> 440519 Removing and installing wheel Removal and Replacement.
3. Remove front wheel housing liner at the right. -> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair.
4. Remove both air cowls for air-cleaner box. -> 242719 Removing and installing air box for air cleaner - section on "Removing" 242719 Removing and installing air box for air cleaner.
5. Remove radiator frame -> 192019 Removing and installing cooling fan housing (radiator frame) - section on "Removing" 192019 Removing and installing cooling fan housing (radiator frame). On vehicles with PDCC, unclip the lines on the front-axle carrier.
6. Drain coolant -> 193817 Draining and filling coolant (includes bleeding) Service and Repair.
6.1. Remove coolant hose at the water connection piece for the front of the engine (coolant hose from engine to radiator).
7. Loosen drive belt -> 137819 Removing and installing drive belt Service and Repair.
8. Remove drive-belt deflection roller.
Additional scope for turbo engines:
9. Remove pressure and suction hoses close to cylinder 1-4 -> 214119 Removing and installing pressure pipe .
9.1. Remove pressure pipes at the top in front of the throttle valves.
9.2. Remove the lower right pressure pipe (direction of travel) between the charge-air cooler and turbocharger.
9.3. Remove the right intake pipe (direction of travel) at the bottom in front of the turbocharger.
Removing generator
Installation position of generator (example)
1. Unscrew fastening screw -3- on the impact bracket -1-.
Right impact bracket (top view)
2. Loosen turbocharger control line -4-.
3. Unscrew fastening screws -1, 2- on the impact bracket -3-.
Left impact bracket (top view)
4. Remove the impact bracket.
5. Loosen the fastening screw -1- for the ground strap -2- on the generator.
Loosening ground strap
5.1. Unscrew fastening screw -1-.
5.2. Remove ground strap -2- from the generator -arrow-.
6. Close off the coolant hoses -1 and 2- with a hose clamp -3- to prevent them from leaking.
Closing off coolant hoses with hose clamp
Information
Always replace the sealing rings for the coolant connection piece on the generator.
7. Loosen supply connection piece on generator.
7.1. Unscrew fastening screw -2- on the supply connection piece -1-.
7.2. Remove supply connection piece -1- from the generator -arrow-.
7.3. The return connection piece remains fitted on the generator. When replacing the generator, this will be removed and fitted on the new generator with new seals.
Removing supply connection piece on generator
8. Unscrew the three fastening screws -2, 3- on the generator.
Unscrew the fastening screws -2- first.
Generator
9. Remove heat shield for generator lines. To do this, turn the generator (in direction of travel) away to the right side of the engine. This is the best way to reach the screws on the retaining bracket.
9.1. Unclip electric lines for the generator and oxygen sensor at the heat shield -1- ( -arrows A- ).
9.2. Unscrew fastening screw -2-.
9.3. Open the retaining clip -3- ( -arrow B- ) and remove the B+ line -4- ( -arrow C- ).
9.4. Lift heat shield -1- up and remove it -arrow D-.
Removing heat shield for generator lines
10. Remove B+ line on the generator.
10.1. Screw off fastening nut -1-.
10.2. Remove B+ line -2- from the generator -arrow-.
Removing B+ line on generator
11. Disconnect plug connection for generator.
11.1. Release plug connection for generator -1- ( -arrow A- ) and disconnect it -arrow B-.
11.2. Pull off plug connection for generator -1- and the line bracket from the B+ line -arrow C-.
Disconnecting plug connection for generator
12. Pull the generator forward.
13. Remove the generator -1- from the vehicle.
Removing generator
13.1. Protect the radiator and cylinder head from damage by covering them with a piece of cardboard, for example.
13.2. Move the generator -1- forward and lift it up out of the vehicle -arrow-.
Installing generator
Information
Always replace the sealing rings for the coolant connection piece on the generator.
- The generator is installed in reverse order to removal.
1. Fit the retaining bracket:
1.1. Fit the generator.
1.2. Position the retaining bracket and fix in place with the fastening screw.
1.3. The generator is screwed to the engine.
1.4. Insert B+ line into the retaining clip and secure it to the generator.
1.5. Only now should you lift the retaining bracket against its stop and tighten the fastening screw.
- Always comply with the specified tightening torques -> 1001TW Tightening torques, tightening sequences, assembly overviews [1][2]Specifications.=> Tightening torque: 23 Nm (17 ftlb.) => Tightening torque: 10 Nm (7.5 ftlb.)+90°
Subsequent work
Additional scope for turbo engines:
1. Install pressure and suction hoses close to cylinder 1-4 -> 214119 Removing and installing pressure pipe .
1.1. Install the right intake pipe (direction of travel) at the bottom in front of the turbocharger.
1.2. Install the lower right pressure pipe (direction of travel) between the charge-air cooler and turbocharger.
1.3. Install pressure pipes at the top in front of the throttle valves.
2. Install drive-belt deflection roller.
3. Install drive belt -> 137819 Removing and installing drive belt Service and Repair.
4. Install air cowls for air-cleaner box -> 242719 Removing and installing air box for air cleaner 242719 Removing and installing air box for air cleaner.
5. Fill in coolant -> 193817 Draining and filling coolant (includes bleeding) Service and Repair.
6. Install radiator frame -> 192019 Removing and installing cooling fan housing (radiator frame) - section on "Installing" 192019 Removing and installing cooling fan housing (radiator frame). On vehicles with PDCC, clip in the lines on the front-axle carrier.
7. Install front wheel housing liner at the right. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair.
8. Fit right front wheel -> 440519 Removing and installing wheel Removal and Replacement.
9. Connect the battery -> 2X00IN Work instructions after disconnecting the battery 2X00IN Work instructions after disconnecting the battery.