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Remove/install generator belt pulley - AR15.40-P-5710EB

ENGINE 612.963 in MODEL 163 (Generator with freewheel) 

ENGINE 166.990 /995, 668.940 /941 /942 in MODEL 168 (Generator with freewheel) 

ENGINE 604.910 /915, 605.910 /960 as of 1.6.97, 611.960 in MODEL 202 (Generator with freewheel) 

ENGINE 602.982 as of 1.12.95, 604.912 /917, 605.912 as of 1.6.97, 605.962, 606.912 as of 1.6.97, 606.962, 611.961, 612.961, 613.961 in MODEL 210 (Generator with freewheel) 

ENGINE 668.914, 166.991 in MODEL 414 (Generator with freewheel) 

Fig 1: Identifying Generator Belt Pulley Components
G04631774Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/Install     
1 Remove alternator Engine 612 in model 163. AR15.40-P-5032GI
    Engine 611 as of 1.6.99, 612, 613. AR15.40-P-5032EC
    Engine 668 up to 28.2.01, 166 in model 168. AR15.40-P-5032GF
    Engine 668 in model 168 as of 1.3.01. AR15.40-P-5032GC
    Engine 604, 605, 611 in model 202. AR15.40-P-5032EA
    Engines 602, 611 up to 31.5.99, 604, 605, 606 in model 210. AR15.40-P-5032F 
    Engine 668.914 in model 414.700 AR15.40-L-5032VA
    Engine 166.961/ 991 in model 414.700 AR15.40-L-5032VB
2 Remove covering cap (4) NOTESInstallation:  Install new cap as it is damaged when it is pulled off.  
3 Unscrew poly-V-belt pulley (1) using cap wrench (3) IMPORTANT Counterhold the alternator shaft (2) using triple square socket or Allen nut.  
    SPECIAL TOOL Fig 2
    IMPORTANT When replacing alternators after mileages in excess of 100 000 km (60,000 miles), replace the ribbed V-belt pulley at the same time.  
    TORQUE SPECIFICATION Engines 166.990/995 *BA15.40-P-1003-01B 
    TORQUE SPECIFICATION Engine 668 *BA15.40-P-1003-01C 
    TORQUE SPECIFICATION Engines 611, 612, 613 *BA15.40-P-1004-01D 
    TORQUE SPECIFICATION Engines 602, 604, 605, 606 *BA15.40-P-1004-01E 
4 Install in the reverse order    
TORQUE SPECIFICATION Alternator

Number Designation Engine 166.940/ 960/990/ 995
BA15.40-P-1003-01B Collar nut to poly-V-pulley Nm 80
TORQUE SPECIFICATION Alternator

Number Designation Engine 668.940 until 28.02.01, 668.941 Engine 668.940 as of 01.03.01, 668.942
BA15.40-P-1003-01C Collar nut to poly-V-pulley Nm 80 75
TORQUE SPECIFICATION Alternator

Number Designation Engine 602 Engine 604 Engine 605 Engine 606
BA15.40-P-1004-01E Collar nut to poly V-belt pulley Nm 80 80 80 80
TORQUE SPECIFICATION Alternator

Number Designation Engine 611.960 611.961 to 31.5.99 611.981/983/987 612.981 Engine 611.961 as of 1.6.99 612.961/963 Engine 613
BA15.40-P-1004-01D Collar nut to poly V-belt's belt pulley Nm 80 80 80
Fig 2: Identifying Socket Wrench (602 589 00 10 00)
G04631775Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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