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Alternator Swap - OM602. 1991 300D 2.5 Diesel Turbo
After reading this thread on W123 alternator swaps combined with the fact that my 124 has always seemed to have low voltage I decided to look for a possible Mercedes replacement unit.
The one I selected (because it was given to me) came from a 1990 Mercedes-Benz 300TE 4matic and rated at 80 AMP vs. the 50 AMP unit in mine from the factory. Before beginning the swap I had the donor unit tested at a local auto parts store and it passed! To be safe I elected to replace the regulator & brushes before installing it on the car. The case was the same size and same bolt pattern as the old unit - in fact even the pulley was the same! One change did need to be made, the case needed to be rotated 90 degrees so that the connection point for the wires allowed proper routing of the wires. The factory wiring for the 50 AMP alternator was very light gauge wire. In fact so light I decided to upgrade the alternator harness with a homemade harness comprised of dual 4 gauge wires. Another reason for a new harness was because the old unit used a connector that was incompatible with the new unit. The final reason is that since I haven't molested the original its easy to return to factory if it's ever needed. I reused the heat shield to route my new harness then added split loom tubing to protect the new wires. And 6 hours later the job was complete. There isn't much to see, but photos of the swap are on my Benz-Site. |
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have also a 91 300D 2.5turbo which has an alternator made by Valeo. So far, no issues but
concerned brushes of volt. regulator worn. If you removed a Valeo wondering whether you can give me the number on the voltage regulator. Tried to buy a new one but parts dealers asking for a number. Thanks for your assistance. |
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For others, here's some tips for upgrading the wiring - Installed a 143A alternator in my W124 (86-95E-class) - with photos
Sixto 87 300D |
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Valeo alternators
Quote:
The Valeo alternator is M-B part number 011 154 62 02; the regulator carries Valeo part number 2545472. I earched for a replacement regulator and found it almost impossible to find. I have been told that M-B dealers can get them but the price is ~$100, three times what I paid for the alternator! A local alternator/starter rebuilding shop was able to sell me a pair of brushes for $10. They are not exact replacements but will fit and work and I can install them myself. You might try the same thing -- take the regulator out and have an auto electric shop in your area look it over. They may be able to cross it to an available replacement regulator, install new brushes, or sell you brushes to install yourself. Take the alternator too, in case they want to see it. Good luck, I think I'll avoid Valeo in the future. Jeremy
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"Buster" in the '95 Our all-Diesel family 1996 E300D (W210) . .338,000 miles Wife's car 2005 E320 CDI . . 113,000 miles My car Santa Rosa population 176,762 (2022) Total. . . . . . . . . . . . 627,762 "Oh lord won't you buy me a Mercedes Benz." -- Janis Joplin, October 1, 1970 |
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diesel friend: My old alternator was a Bosch. I'd be glad to supply the part # off the regulator when I get home, but it doesn't sound like that will help.
sixto: The harness that gsxr made looks very similar to the one I made. Great minds think alike! |
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Hmmm this is interesting as I was wondering what the 602 had on it for an alt..
I upgraded my M103 to a 143A unit a few years ago. The 602 has a new alternator on it so I probably wont be installing anything to replace that for a while. But if I did it would be a 143a unit if it fits that is...
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Cruise Control not working? Send me PM or email (jamesdean59@gmail.com). I might be able to help out. Check here for compatibility, diagnostics, and availability! (4/11/2020: Hi Everyone! I am still taking orders and replying to emails/PMs/etc, I appreciate your patience in these crazy times. Stay safe and healthy!) 82 300SD 145k 89 420SEL 210k 89 560SEL 118k 90 300SE 262k RIP 5/25/2010 90 560SEL 154k 91 300D 2.5 Turbo. 241k 93 190E 3.0 235k 93 300E 195k |
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JamesDean if I hadn't been given the 80 AMP unit the donor would have most likely been a larger capacity. At this point installing a different unit should be a snap since the new harness is fabricated and installed.
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I put a 143A on my 603. Drop in fit, sans wiring obviously.
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I'm not a doctor, but I'll have a look. '85 300SD 245k '87 300SDL 251k '90 300SEL 326k Six others from BMW, GM, and Ford. Liberty will not descend to a people; a people must raise themselves to liberty.[/IMG] |
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I have been told by a very experienced auto elec that you can upgrade your bosch alt by simply replacing the reg with a reg that is for the higher amperage. The rotor excitation voltage is low enough so that even with the higher current it doesnt get near 12v. The core is the same dimensions & material so its unlikely magnetic saturation would be an issue.
Having pulled a few bosch alts to bits, I havent found any difference between the internals of a 60 amp & an 80 amp. Has any one else tried this?
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Grumpy Old Diesel Owners Club group I no longer question authority, I annoy authority. More effect, less effort.... 1967 230-6 auto parts car. rust bucket. 1980 300D now parts car 800k miles 1984 300D 500k miles 1987 250td 160k miles English import 2001 jeep turbo diesel 130k miles 1998 jeep tdi ~ followed me home. Needs a turbo. 1968 Ford F750 truck. 6-354 diesel conversion. Other toys ~J.D.,Cat & GM ~ mainly earth moving |
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Quote:
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Alt. swap OM 602
Thanks for all the help. Was able to obtain a used 80 AMP Bosch out of a 190E,
2.6. and the brushes of the volt. reg. have quite a bit of life left. |
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Late 124 diesel alternator swapping
Quote:
Incidentally, the regulators were not interchangeable -- physically different. Jeremy
__________________
"Buster" in the '95 Our all-Diesel family 1996 E300D (W210) . .338,000 miles Wife's car 2005 E320 CDI . . 113,000 miles My car Santa Rosa population 176,762 (2022) Total. . . . . . . . . . . . 627,762 "Oh lord won't you buy me a Mercedes Benz." -- Janis Joplin, October 1, 1970 |
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