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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Scott C.

2006 E320 CDI (120k miles)
FOR SALE: 1998 E300 Turbo Diesel - Black w/Tan Leather - Euro delivery (236k miles)

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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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

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)

Attached Thumbnails

 

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Scott C.

2006 E320 CDI (120k miles)
FOR SALE: 1998 E300 Turbo Diesel - Black w/Tan Leather - Euro delivery (236k miles)

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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#dieselFLEET
---------------
'97 E300
'99 E300

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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01 Ford Excursion Powerstroke
99 E300 Turbodiesel
91 Vette with 383 motor
05 Polaris Sportsman 800 EFI
06 Polaris Sportsman 500 EFI
03 SeaDoo GTX SC Red
03 SeaDoo GTX SC Yellow
04 Tailgator 21 ft Toy Hauler
11 Harley Davidson 883 SuperLow

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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Marty D.

2013 C300 4Matic
1984 BMW 733i
2013 Lincoln MKz

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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1988 190E Sold
1996 C230K Sport Sold
His: 98 E300TD Estate, 7 seater, Avantgarde, Silver, Black cloth, parameter steering, dipping rvm, folding mirrors, rain sensing wipers, pentagon tints, 17" Elegance wheels. 298K
Hers: 93 300TD, 7 seater, Grey MB Tex pearl blue metallic, 15" 8 hole alloys, OTG, Cruise, not much else 220K

Thanks for the input guys - much appreciated. I'm putting my wife to work with me to do this job tomorrow I hope. I'll work from below and I'm thinking she can work from above to put the upper bolt in place while I hold the alternator in place.

McCool - question for you on Post #6 in the link you gave. In your instructions you say "NB Charge pipe needs removed to get alternator off car." What does the NB refer to?

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Len
'59 220S Cabriolet-SOLD and living happily in Malta
'83 240D 351,500 miles original owner-SOLD
'88 560SL 41,000 miles - totaled and parted out
https://sites.google.com/site/mercedesstuff/home
'99 E300 turbo 227,500 miles
'03 SLK320 40,000 miles - gave to my daughter
'14 Smart electric coupe 28,500 miles
'14 Smart electric cabriolet 28,500 miles
'15 Smart electric coupe 28,000 miles