Alternator: Service and Repair
Remove and install generator
DANGER:
- Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries.
- No fire, sparks, naked flames or smoking. Wear acid-resistant gloves, clothing and glasses. Pour battery electrolyte only into suitable and appropriately marked containers.
1 Disconnect battery ground line
CAUTION: Do not connect quiescent current retention unit!
2 Remove air pump (5)
3 Drain coolant
4 Remove fan shroud
5 Remove engine compartment paneling
6 Remove poly-V-belt (4).
7 Unscrew nut on the cable terminal 30 (1) and remove cable
- Nut of terminal B+ to generator: 15 Nm
8 Release clutch cable terminal 61 (2) and detach.
9 Dismount cable bracket (3)
10 Dismount coolant hose at coolant pump (6).
11 Unscrew bolt of alternator (7).
- Bolt of cooler housing of generator to crankcase
- M7: 14 Nm
- M8: 20 Nm
12 Dismount coolant hose from connection (8) at generator (G2)
13 Dismount cable bracket for coolant hose (9).
NOTE: Installation: Fasten cable bracket for coolant hose (9) before installing alternator at generator.
14 Dismount bracket of transmission oil line (11)
15 Dismount bracket of oil dipstick (10) from alternator.
16 Unscrew bolts of alternator (12, 3 pieces)
- Bolt of cooler housing of generator to crankcase
- M7: 14 Nm
- M8: 20 Nm
17 Remove coolant expansion reservoir
18 Remove windshield washer fluid reservoir
19 Slacken both engine mounts at front axle carrier
- Bolt of front engine mounts to front axle carrier: 35 Nm
20 Lift engine
NOTE: It is sufficient to move engine to the side, in order to achieve better accessibility to the alternator.
21 Lift generator (G2) up and out
22 Replace sealing ring for flange (13)
23 Install in reverse sequence.
24 Carry out functional test
25 Render electrical system operational
NOTE: Perform basic programming (normalize windows and sliding roof, etc.).