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  #1  
Old 02-17-2008, 11:27 AM
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Location: North Shore, MA
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W210/OM606 turbo: Alternator removal

Well, it lasted for 135k miles so I'm not complaining that my alternator needs to be rebuilt. Very nice alternator too - 115A Bosch (0 123 510 080) but not cheap (paid $385 + $110 core charge). While I'm waiting for the new one to arrive I figure I'd remove the old one in the meantime. I figure I'll outline my removal process so far then get to my question...

1) Remove negative terminal on battery (actually, I removed them both - they need to be cleaned up anyway)
2) Remove cable connectors from back of alternator
3) Remove bolt on spring pivot on belt tensioner
4) Remove belt from alternator pulley (remove from power steering pump first - makes it easier)
5) Remove top bolt on alternator - female Torx (E14)
6) Swing alternator downward to frame cross-member - opens up just enough space to get wrench on bottom alternator bolt
7) Remove bottom bolt on alternator

OK, now for my question - how do get the alternator from it's current location to my workbench? There is something in the way in every direction - frame crossmember and intercooler pipe below, turbo above and behind, and coolant port on engine infront. Which one of these should be removed - or am I missing something here?

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2006 E320 CDI (120k miles)
FOR SALE: 1998 E300 Turbo Diesel - Black w/Tan Leather - Euro delivery (236k miles)
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Old 02-17-2008, 01:19 PM
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Haven't done this one mine.

Looks like the only chance is to work it out down and to the rear; but, also looks like you might have to remove some stuff too.
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09' Hyundai Santa Fe Diesel 48k (S.A.)
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Old 02-17-2008, 09:19 PM
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Agreed - looks like 'down and out' is the only way to remove it. Turns out that the pipe from the turbo to the intercooler is only held in place by 3 short bolts. After removing the pipe clamps it came out fairly easy.

Oh, and a spray can plastic top is a perfect fit as a protective cap for the turbo intake (see pic)
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W210/OM606 turbo: Alternator removal-img_0534.jpg  
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2006 E320 CDI (120k miles)
FOR SALE: 1998 E300 Turbo Diesel - Black w/Tan Leather - Euro delivery (236k miles)
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Old 02-17-2008, 11:14 PM
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Looks like you got it out of there. When I replaced mine it was cake since mine does not have the intercooler hose.

I noticed that for the '98-'99 there is a 90 amp unit and a 115 amp unit. When I replaced mine I went with the 90amp instead of potentially upgrading to a higher output unit since I had an additional amplifier and it just seemed that my '97 takes so much longer to recharge the battery after startup, etc. that our '99, which I feel has the 115 amp output unit....

Any thoughts folks?
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Old 02-18-2008, 08:19 AM
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I have done this twice before. Once when I had the bearings rebuilt and the 2nd time when I replaced the alternator. You HAVE TO remove the intercooler pipe and it will be done real easy
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Old 02-18-2008, 10:29 AM
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Quote:
Originally Posted by michakaveli View Post
Looks like you got it out of there. When I replaced mine it was cake since mine does not have the intercooler hose.

I noticed that for the '98-'99 there is a 90 amp unit and a 115 amp unit. When I replaced mine I went with the 90amp instead of potentially upgrading to a higher output unit since I had an additional amplifier and it just seemed that my '97 takes so much longer to recharge the battery after startup, etc. that our '99, which I feel has the 115 amp output unit....

Any thoughts folks?
I don't really understand what you are asking/saying. Normally I would recommend going with the higher output alternator assuming the wiring can handle the extra current, but that might not be the case if your car originally came with a 90A alt it might only have wiring to handle 90A.

You might need to upgrade both the alternator and the wire harness to it to handle the extra current. I think mine has the original 90A valejo alternator and it has no trouble keeping the battery charged under normal circumstances. Should the need arise to replace it I will likely use the same size just since I don't need more than the 90A it puts out.
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Old 02-18-2008, 05:30 PM
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Hi

I had posted on this before but was too late this time to help. Glad you got it sorted.

1999 e300td alternator replacement

McCool300TD

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