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Remove/install alternator - AR15.40-P-5032GZB

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ENGINES 642 in MODEL 164 

Shown on engine 642 without code U42 BLUETEC diesel exhaust gas cleaning 

Fig 1: Identifying Alternator Components - Without Code U42 BLUETEC Diesel Exhaust Gas Cleaning
G06878128Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on engine 642 with code U42 BLUETEC diesel exhaust gas cleaning 

Fig 2: Identifying Alternator Components - With Code U42 BLUETEC Diesel Exhaust Gas Cleaning
G06878129Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/install     
DANGER Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, lift gates or sliding roof Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A
DANGER Risk of explosion  caused by oxyhydrogen gas. Risk of poisoning and caustic burns  caused by swallowing battery acid. Risk of injury  caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. AS54.10-Z-0001-01A
1 Detach ground line from battery NOTES Insulate clamping device of the ground line in order to prevent inadvertent contact with the ground point of the battery.  
    Model 164 AR54.10-P-0003GZ
    Model 251 AR54.10-P-0003RT
NOTES Notes on battery   AH54.10-P-0001-01A
2 Removes strut tower brace Model 164.8 only
IMPORTANT Remove strut tower brace from strut tower mounts.		 AR62.30-P-2500GY
3 Remove engine trim panel Model 164 AR01.10-P-2405GZB
    Model 251 AR01.10-P-2405RTB
4 Remove right engine intake air duct    
5 Remove charge air hose downstream of the charge air cooler IMPORTANT Charge air hose on the right. AR09.41-P-8625GZB
6 Partly remove poly - V belt IMPORTANT Only remove poly - V belt from belt pulley on alternator (G2). AR13.20-P-0001GZB
7 Remove bolts (3) on alternator (G2) TORQUE SPECIFICATION *BA15.40-P-1001-01D 
8 Detach electrical line (1) IMPORTANT By pulling alternator (G2) with attached electrical lines forwards.  
    TORQUE SPECIFICATION *BA15.40-P-1002-01D 
9 Press circulation pump over alternator (G2) with attached lines to the side    
10 Disconnect electrical connector (2)    
11 Disconnect electrical connector to electrical fan shroud    
12 Remove circulation pump with holder on longitudinal member IMPORTANT Only for model 164 and 251 with code U42 BLUETEC diesel exhaust gas cleaning.  
13 Unclip coolant line on electrical fan shroud    
14 Take alternator (G2) down and out IMPORTANT Remove oil dipstick if necessary.  
15 Install in the reverse order    
DANGER Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.		 AS00.00-Z-0005-01A
16 Carry out engine test run    
ALTERNATOR

Number Designation Engine 642
BA15.40-P-1001-01D Bolt, alternator to timing case cover Nm 20
BA15.40-P-1002-01D Nut of circuit B+ to alternator Nm 15
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