Remove/Install Integrated Starter Alternator - AR15.40-P-0003MSC

Engine 256.9 In Model 167

MODIFICATION NOTES

27.09.2019

Measurement of phase resistances

BE15.40-P-1002-06MRT

Fig 1: Integrated Starter Alternator Components Location - Engine 256.9 In Model 167

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	Risk of injury To skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°. Open cap slowly and release the overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on safety-relevant components		AH00.00-Z-0019-01A
	Remove
1	Remove transmission.	Engine 256.9 in model 167 with transmission 7250	AR27.10-P-0500MSC
2	Remove starter-alternator control unit (N129).		AR15.40-P-0004MSC
3	Remove screw (6) and guide sensor connector of integrated starter-alternator (A79) through opening at timing case.	WIS Service Media multimedia:A supplement to the article is available. Operation steps 4 to 22 are shown.
4	Remove screws (15) in reverse order to tightening procedure and remove centering flange (16).	Tightening procedure of integrated starter alternator Aid of helper required.	AR15.40-P-0003-01MRT
		Counterholder	Fig 5
5	Remove crankshaft Hall sensor (B70).		AR15.12-P-2136MSC
6	Clamp off coolant lines from the coolant inlet fitting (11).	Clamp	Fig 3
7	Remove screws (10) and remove coolant inlet fitting (11).
8	Remove breather connection (17).
9	Turn Engine in direction of Engine rotation to TDC marking (ignition TDC) of cylinder 1.	Turn Engine only in the direction of Engine rotation. Engine damage will occur otherwise. The TDC marking on the vibration damper must match with the marking on the crankcase.
		Counterholder	Fig 5
10	Install assembly tool for removal of integrated starter generator (A79).		AR15.40-P-0003-05MRT
	Service Information: Parts identification of mounting plate for removal of integrated starter alternator in XENTRY Portal Parts Information		SI15.40-P-0012A
		Do not remove assembly tool in disassembled status from integrated starter alternator (A79). Integrated starter alternator (A79) will otherwise be damaged. Order assembly tool as a replacement part.
		Counterholder	Fig 5
11	Install support fixture.
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
		Support fixture	Fig 2
12	Remove screws (18).
13	Remove integrated starter alternator (A79).	Do not damage sensor connector of integrated starter alternator (A79). The function of the integrated starter alternator (A79) is otherwise not ensured. Integrated starter alternator (A79) must not come into contact with fluids. The function of the integrated starter alternator (A79) is otherwise not ensured.
	Install
14	Install integrated starter alternator (A79).	When inserting integrated starter alternator (A79), ensure that sensor connector of integrated starter alternator (A79) is not damaged. The function of the integrated starter alternator (A79) is otherwise not ensured.
15	Tighten bolts (18).	Bolt, stator housing to timing case	*BA15.40-P-1001-02MRT
16	Remove support fixture.
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
		Support fixture	Fig 2
17	Remove assembly tool for removal of integrated starter alternator (A79).		AR15.40-P-0003-05MRT
		Bolt, integrated starter alternator to crankshaft	*BA15.40-P-1003-02MR T
		Bolt, stator housing to timing case	*BA15.40-P-1001-02MR T
		Counterholder	Fig 5
	Measure
18	Perform resistance measurement for coils.		AR15.40-P-0003-04MRT
		Measurement of phase resistances	*BE15.40-P-1002-06MRT
	Install
19	Guide sensor connector of integrated starter alternator (A79) through opening at timing case and install with screw (6) at timing case.	Bolt, sensor connector to timing case	*BA15.40-P-1007-02MRT
20	Install centering flange (16).	Tightening procedure of integrated starter alternator Replace centering flange (16). Aid of helper required.	AR15.40-P-0003-01MRT
		Bolt, integrated starter alternator to crankshaft	*BA15.40-P-1003-02MRT
		Bolt, centering flange to crankshaft	*BA15.40-P-1002-02MRT
		Counterholder	Fig 5
21	Measure air gap between stator and rotor.		AR15.40-P-0003-03MRT
		Clearance measurement	*BE15.40-P-1001-06MRT
		Gauge If problems exist ↓ Replace integrated starter alternator (A79)	Fig 4
22	Install starter-alternator control unit (N129).		AR15.40-P-0004MSC
23	Install crankshaft Hall sensor (B70).		AR15.12-P-2136MSC
24	Install coolant inlet fitting (11) and remove clamps from coolant lines.	Bolt, coolant entry fittings to timing case	*BA15.40-P-1006-02MRT
		Clamp	Fig 3
25	Install breather connection (17).
26	Install transmission.	Engine 256.9 in model 167 with transmission 725.0	AR27.10-P-0500MSC
27	Check Engine cooling system for leak tightness.		AR20.00-P-1010MSC
28	Connect diagnostic device and perform venting routine.
			AD00.00-P-2000-06ME
29	Check coolant level and correct.	Coolant mixing ratio	*BF20.00-P-1001-04A
30	Perform commissioning of starter-alternator control unit (N129).	When replacing integrated starter alternator (A79).
			AD00.00-P-2000-06ME
	Risk of accident from vehicle starting off by itself when Engine running. Risk of injury (bruises and burns) resulting from working on the Engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
31	Carry out engine test run and check engine for proper operation and leak tightness.
32	Install lower Engine compartment lining.		AR61.20-P-1105ME

TEST SPECIFICATIONS OF INTEGRATED STARTER ALTERNATOR

Number	Designation			Engine 256.9
BE15.40-P-1001-06MRT	Clearance measurement	Gap between stator and rotor	mm	0, 9

TEST SPECIFICATIONS OF INTEGRATED STARTER ALTERNATOR

Number	Designation			Engine 256.9
BE15.40-P-1002-06MRT	Measurement of phase resistances	Resistances of phases U-V, V-W, W-U	mΩ	9, 1 ±0, 3
		Resistances of phases X-Y, Y-Z, Z-X	mΩ	8, 7 ±0, 3
		For picture, see		AR15.40-P-0003-04MRT

STARTER-ALTERNATOR

Number	Designation			Engine 256
BA15.40-P-1001-02MRT	Bolt, stator housing to timing case	Stage 1	Nm	20
BA15.40-P-1001-02MRT	Bolt, stator housing to timing case	Stage 2	∠°	60

STARTER-ALTERNATOR

Number	Designation			Engine 256
BA15.40-P-1002-02MRT	Bolt, centering flange to crankshaft	Stage 1	Nm	45
BA15.40-P-1002-02MRT	Bolt, centering flange to crankshaft	Stage 2	∠°	90

STARTER-ALTERNATOR

Number	Designation			Engine 256
BA15.40-P-1003-02MRT	Bolt, integrated starter alternator to crankshaft	Stage 1	Nm	45
BA15.40-P-1003-02MRT	Bolt, integrated starter alternator to crankshaft	Stage 2	∠°	90

STARTER-ALTERNATOR

Number	Designation		Engine 256
BA15.40-P-1006-02MRT	Bolt, coolant entry fittings to timing case	Nm	8

STARTER-ALTERNATOR

Number	Designation		Engine 256
BA15.40-P-1007-02MRT	Bolt, sensor connector to timing case	Nm	8

COOLANT MIXING RATIO

Number	Designation				All Engines, except Engine 178 in model 190.381
BF20.00-P-1001-04A	Coolant mixing ratio	Antifreeze/water	Up to -25°	%	-
			Up to -37°	%	50/50
			As of -38°	%	55/45
			Overview and specifications sheet		BB00.40-P-0310-01A
			References to sheet specification		BB00.40-P-0310ZZ

Fig 2: Identifying Support Fixture (256 589 01 31 00)

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Fig 3: Identifying Clamp (000 589 40 37 00)

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Fig 4: Identifying Gauge (256 589 01 23 00)

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Fig 5: Identifying Counterholder (654 589 00 40 00)

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