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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Mercedes-Benz G-Class (W463, 1999 issue)
general info. full specifications. diagnostics. hints. tips. tricks
 Mercedes-Benz G-class
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G-class
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general information
Battery - general information, tips for maintenance
Charging System - general information and safety measures
Check the charging system
Removing and installing the generator
The system start the engine - the general information and precautions
Removing and installing starter
Automatic Transmission
Transmission Line
Brakes and auxiliary systems
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Removing and installing the generator



Petrol models

Details of the installation of the generator in the petrol models

1 - Air Cleaner
5 - wire terminal 30 (B +)
6 - conductor terminal 61 (D +)
7 - Bolts

8, 9 - Nuts
G2 - Generator
M13 - Circulation pump cooling system

PERFORMANCE ORDER

  1. Disconnect the negative wire from the battery.
  2. Remove the air cleaner (1) (see chap. Power supply system and exhaust).
  3. Loosen the belt and throw off it with the alternator pulley.
  4. Remove from valve cover and take the direction of the guide tube of the probe.
  5. Remove installed in the wheel housing of the cooling system circulating pump (M13).
  6. Remove the mounting bolts (7), remove the generator (G2) with support bracket and set it aside.
  7. Disconnect the wiring (5, 6), and finally remove the generator (G2).
  8. Installation is in the reverse order.
  9. Finally, clean the processor memory on-board self-diagnostic system (see. Section General information).

Diesel models

Models 463.323 (M612)

Details of the installation of the generator models 463.323 (M612)

1 - Connector
2 - Electrical circuit 30
3, 4, 8 - Bolts

5 - the turbocharger oil
6, 7 - Lines Coolant
G2 - Generator

PERFORMANCE ORDER

  1. On models corresponding complete set (code ET2) activate the service mode of the emergency call TELE AID (see. Section Activate / deactivate the service mode of the emergency call AID TELE).
  2. Connect to a standard auxiliary battery pack.
  3. Disconnect the negative wire from the battery.
  4. Poddomkratte car and establish it on props.
  5. Remove protection crankcase.
  6. Drain the cooling system (see chap. Current care and maintenance).
  7. Remove the trim panel to the cylinder head cover.
  8. Remove the air cleaner (see chap. Power supply system and exhaust).
  9. Remove the accessory drive belt (see chap. Engine).
  10. Remove the air duct system pressurization.
  11. Disconnect the connector (1) electrical circuit 61.
  12. Disconnect the wiring circuit 30 (2).
  13. Remove the bolt (3) of the support bracket.
  14. Remove the bolt (4) and remove the cooling fluid supply line (on the crankcase of the engine and the turbocharger), also remove the coolant supply line (6), - Prepare removable sealing elements.
  15. Remove the bolt from the bracket (7).
  16. Remove the mounting bolts (8) and pulling down, remove the generator (G2), - prepare a replacement gasket is installed between the flange and the cooling jacket of the engine block. If necessary, remove the drive pulley (cm. Below).
  17. Installation is performed in reverse order - do not forget to replace the sealing elements.
  18. Deactivate the service mode of TELE AID and clean the processor memory board self-diagnostic system (see. Section General information).
  19. Finally, start the engine and check for signs of coolant leaks.

Models 463.333 (M628)

Water Cooled Generator

Details of the installation of the generator, water-cooled models 463.333 (M628)

1 - Air Cleaner
2 - Air intake
3 - Cover
4 - Hoses cooling path
5, 6, 9 - Screws
7 - Connector wiring

8 - the nut to the generator terminals B +
10 - Support bracket
11, 12 - Bolts
13 - Cover the cooler
G2 - Generator

PERFORMANCE ORDER

  1. On models corresponding complete set (code ET2) activate the service mode of the emergency call TELE AID (see. Section Activate / deactivate the service mode of the emergency call AID TELE).
  2. Disconnect the negative wire from the battery.
  3. Poddomkratte car and establish it on props.
  4. Remove protection crankcase.
  5. Drain the cooling system (see chap. Current care and maintenance).
  6. Remove the air cleaner (1) and an air inlet (2) (see chap. Power supply system and exhaust).
  7. Remove the cover (3).
  8. Remove the fan shroud and radiator cooling system (see chap. System of cooling, heating, ventilation and air conditioning).
  9. Remove the boost air cooler (see chap. Power supply system and exhaust).
  10. In order to ensure access, remove padded front generator (G2) hoses (4) of the cooling path.
  11. Remove the accessory drive belt (see chap. Engine).
  12. Remove the bolt (5) fixing the cooling line path.
  13. Remove the bolt (6) and remove the guide tube of the probe.
  14. Disconnect the wiring connector (7).
  15. Loosen the nut (8) mounting the generator terminals B + and release the wiring.
  16. Remove the bolt (9) fixing the wiring harness.
  17. Remove the mounting bolts (11) and remove the support bracket (10) control module.
  18. Remove the bolts (12) securing the cooler housing (13).
  19. Press the generator (G2) in gathering with a casing cooler (13) to the right and, leaning forward, remove it from the engine compartment - Prepare the replacement O-rings.
  20. Installation is in the reverse order. Ensure integrity of planting guide tube and the probe is properly connected to the inlet air cleaner (2).
  21. Finally, deactivate the service mode of TELE AID, clean the processor memory on-board self-diagnostic system (see. Section General information) and check the engine for signs of coolant leaks.

Generator, air-cooled

Details of installation of a generator, air-cooled models 463.333 (M628)

1 - Air Cleaner
2 - Air intake
3 - Cover
4 - Hoses cooling path
7 - Connector wiring
8 - the nut to the generator terminals B +

9 - Wiring
10 - Support bracket
11, 12 - Bolts
G2 - Generator

PERFORMANCE ORDER

  1. On models corresponding complete set (code ET2) activate the service mode of the emergency call TELE AID (see. Section Activate / deactivate the service mode of the emergency call AID TELE).
  2. Disconnect the negative wire from the battery.
  3. Poddomkratte car and establish it on props.
  4. Remove protection crankcase.
  5. Drain the cooling system (see chap. Current care and maintenance).
  6. Remove the air cleaner (1) and an air inlet (2) (see chap. Power supply system and exhaust).
  7. Remove the cover (3).
  8. Remove the fan shroud and radiator cooling system (see chap. System of cooling, heating, ventilation and air conditioning).
  9. Remove the boost air cooler (see chap. Power supply system and exhaust).
  10. In order to ensure access, remove padded front generator (G2) hoses (4) of the cooling path.
  11. Remove the accessory drive belt (see chap. Engine).
  12. Disconnect the wiring connector (7).
  13. Loosen the nut (8) mounting the generator terminals B + and release the wiring (9).
  14. Remove the mounting bolts (11) and remove the bracket (10).
  15. Remove the bolts (12) and remove the generator (G2), if necessary, remove the drive pulley (see. Below).
  16. Installation is in the reverse order.
  17. Finally, deactivate the service mode of TELE AID, clean the processor memory on-board self-diagnostic system (see. Section General information) and check the engine for signs of coolant leaks.

Dismantle the drive pulley

Alternator pulley must be replaced on a mandatory basis if the mileage of its use in excess of 100 000 km.

Details of the installation of the drive pulley of the generator on diesel models

1 - Pulley
2 - Shaft Generator

3 - Sensing head
4 - Plug

PERFORMANCE ORDER

  1. Remove the generator (See above.).
  2. Remove the plug (4), - the plug must be replaced without fail.
  3. With the end of the head (3) otboltite pulley (1), - the shaft (2) generator Grip using hexagonal or knurled head.
  4. Installation is in the reverse order.





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