Overhaul Disassembly

Overhaul Disassembly on MERCEDES BENZ alternators can be a difficult if you do not approach the process with a plan. As with anything, the more pre-planning involved the fewer mistakes will impact the project though out the disassembly process.

First, remove nut, lock washer, and pulley. Note the position of the spacer(s), and then remove fan assembly followed by the key. Be sure to scribe mark on front and rear housings so the realigning process will be easy. Remove voltage regulator and remove screws holding alternator together. Separate front and rear housings.

Second, disconnect capacitor from terminal. Remove nut, insulator(s), screws and washers. Remove stator assembly. Unsolder stator from diode assembly. Remove the bearing wave washer or “O” ring from rear housing. Be sure to keep above parts well organized for reinstallation.

Third, support front housing and carefully press out rotor. Do not allow the rotor to fall and get damaged. Now remove screws securing bearing retainer. Remove retainer, front bearing and seal. Remove rear bearing from slip ring end of rotor.

If one observes the above steps, disassembly for your MERCEDES BENZ alternators overhaul will be simple and organized. Always take into consideration the safety of you and those around you. Handle all hazardous materials with caution and dispose of any potentially environmentally hazardous materials properly.

Clint Hough is an author and web site publisher on imported car parts and you can get all your Mercedes Benz Parts from our on line catalog for all your Mercedes Car Parts needs at Imported car parts.com

Tags: alternator, brakes, IGNITION SYSTEM., MERCEDES BENZ, pads, PARTS, shocks, shoes, spark plugs, starters, strutsalternator, brakes, IGNITION SYSTEM., MERCEDES BENZ, pads, PARTS, shocks, shoes, spark plugs, starters, struts

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The Mercedes Benz fuel evaporation system is designed to prevent fuel vapor from escaping from the fuel tank and entering the atmosphere. The Mercedes Benz systems include a fuel tank with vapor separator, purge valve, Thermo valve, and charcoal canister and vent valve.

OPERATION EVAPORATION SYSTEM

ENGINE NOT RUNNING

Fuel tank pressure is maintained by the vent valve, which is a pressure relief valve. When engine is off and vapor expands heated by sun, the pressure relief valve in vent valve opens, allowing vapor to escape threw charcoal canister.
As fuel cools down the volume is reduced, creating a vacuum in fuel tank. Below is a preset value, the vacuum portion of the vent valve opens, allowing air and fuel vapor from canister to travel to fuel tank reducing vacuum.
If system malfunction causes fuel tank pressure to increase above 1.5-4.5 P.S.I…
Relief valve portion of filler cap opens to vent excess pressure.

PURGE SYSTEM ENGINE RUNNING

The purge valve is installed in vacuum line between throttle valve housing and the charcoal canister

A vacuum control line is routed from throttle valve housing through a thermo valve and to the purge valve.
When the engine is running, throttle valve position is above idle, and engine coolant is above 122

Tags: Alternator Brakes, mercedes benz parts, pads, shocks, shoes, spark plugs, starters, strutsAlternator Brakes, mercedes benz parts, pads, shocks, shoes, spark plugs, starters, struts

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MERCEDES-BENZ Rear Suspension

Mercedes-Benz rear suspension is independent type with coil springs and 5 individual links. Rear axle carrier is mounted to body at 4 points and supports rear axle assembly.

Shock absorbers and coil springs are mounted on rubber bushings to reduce vibration and noise.
ADJUSTMENT

SPECIFICATIONS & ADJUSTMENTS FOR WHEEL ALIGNMENT

Use self-locking bolts and nuts with plastic coating (micro-encapsulated) only once. Refinish threads with tap prior to screwing in self-locking bolts.

SHOCK ABSORBERS

1. Remove trunk lining. Remove nut and rubber ring of upper shock mount. Raise vehicle on rear axle.
2. Remove holding clamps on spring link and remove cover. Remove lower shock absorber mounting bolt. Pull shock absorber downward and remove from vehicle.

CAUTION: When removing gas shock absorbers while vehicle is raised and axle tension relieved, do not rotate piston rod while loosening main strut nut. This could result in the sudden extension of the piston rod.
Removal

To install, reverse removal procedure.

COIL SPRINGS

1. Raise vehicle and remove rear wheel. Remove holding clamps of spring link cover and remove cover. Insert Spring Tensioner 201 589 00 31 00 with spring Tensioning Plates 201 589 00 63 00. Compress spring until spring link is free of load.
2. Remove shock absorber as previously outlined. Remove rear spring with rubber mount. To install, reverse removal procedure.

Use extreme caution when removing gas pressurized shock absorbers.
Removal & Installation

REMOVAL REAR SUSPENSION & AXLE

1. Raise vehicle and support with safety stands. Remove wheel assemblies. Disconnect exhaust system at flange connection. Remove intermediate lever of parking brake and disconnect cable controls.
2. Disconnect both brake lines and seal. Loosen clamp nut of drive shaft and intermediate bearing on frame floor and remove. Disconnect rear of drive shaft and slide forward, out of centering position. Wire drive shaft to brake cable holder.
3. Remove spring link covering. Remove shock absorbers and coil springs. Loosen torsion bar connection toward rear axle and remove.
4. On vehicles with ABS, drain rear axle. Remove RPM sensor from rear axle housing. Cover magnetic edge of RPM sensor.
5. On vehicles with auxiliary heater, remove electric fuel pump and suspension plate of exhaust. Remove the cable connector from rear axle cross member. Raise rear axle assembly to lift stop. Force water drain hose out of rear axle carrier.
6. On vehicles with CIS-E fuel injection system, pinch fuel suction hose between fuel tank and fuel pump with a clamp. Loosen clamp on fuel hose to accumulator and pump. Remove fuel hose.
7. On all models, remove front and rear rubber mounts on frame floor and remove with stop plate. Lower the rear axle assembly from vehicle.

CAMBER STRUT

1. Raise vehicle and support with safety stands. Rubber mounts of camber strut cannot be replaced individually. If rubber mounts are damaged, replace camber strut.
2. Remove strut-to-axle carrier bolt. Remove strut-to-wheel carrier bolt. Force clamping sleeve of strut out of wheel carrier.
3. Remove camber strut at axle carrier while pulling slightly outward on wheel carrier. Remove strut in a downward direction.
To install, reverse removal procedure. Bleed brake system and adjust parking brake. Ensure differential is filled to proper level.

To install, reverse removal procedure. Axle shaft must be horizontal prior to tightening camber strut nut.

PULLING STRUT

1. Raise vehicle and support with safety stands. Rubber mounts of pulling strut cannot be replaced individually. If rubber mounts are damaged, replace pulling strut.
2. Mark position of eccentric bolt in relation to axle carrier. Using Wrench 201 589 00 03 00, remove strut-to-axle carrier nut. Prior to pulling out eccentric bolt, push wheel carrier in forward direction to slacken.
3. Remove strut-to-wheel carrier bolt. Force clamping sleeve of pulling strut out of wheel carrier. Remove pulling strut.

1. Raise vehicle and support with safety stands. Remove rod-to-wheel carrier nut. Using Puller (201 589 01 33 00) and Thrust Piece (201 589 05 63 00), force track rod from wheel carrier.
2. Mark position of eccentric bolt in relation to axle carrier. Remove rod-to-axle carrier nut. Remove cam disk, eccentric bolt and track rod.

To install, reverse removal procedure. Grease from ball pin and conical seat in wheel carrier. Hold ball pin with an Allen wrench while tightening. Axle shaft must be horizontal prior to tightening tracking rod-to-axle carrier nut.

PUSHING STRUT

1. Raise vehicle and support with safety stands. Remove pushing strut cover. Rubber mounts of pushing strut cannot be replaced individually. If rubber mounts are damaged, replace pushing strut. Remove strut-to-axle carrier bolt. Remove strut-to-wheel carrier bolt with washer and contour disk.
2. Turn strut on rear axle carrier downward. Force clamping sleeve out of wheel carrier. Remove pushing strut.

To install, reverse removal procedure. Axle shaft must be horizontal prior to tightening pushing strut nuts.

SPRING LINK

1. Raise vehicle and support with safety stands. Remove spring link cover. Remove lower shock absorber bolt. Remove torsion bar from spring link. Remove coil spring as previously outlined.
2. Remove spring link-to-axle carrier bolt. Remove spring link-to-wheel carrier bolt. Remove spring link.

To install, reverse removal procedure. Axle shaft must be horizontal prior to tightening spring link nuts.

WHEEL CARRIER

1. Loosen collar nut fastening rear axle shaft prior to lifting vehicle and removing wheel. Using Remover (201 589 00 61 00), remove rear axle shaft out of rear axle shaft flange.
2. Remove brake caliper and hang out of way using a hook. Remove brake disc. Remove intermediate lever of parking brake and disengage cable control. Pull out lock on hand brake cable.
3. Remove camber strut-to-wheel carrier bolt. Force clamping sleeve of strut out of wheel carrier. Remove pulling strut-to-wheel carrier bolt. Force clamping sleeve of pulling strut out of wheel carrier.
4. Mark position of eccentric bolt of pulling strut in relation to axle carrier. Using Wrench (201 589 00 03 00), remove strut-to-axle carrier nut. Remove complete pulling strut.
5. Remove track rod-to-wheel carrier nut. Using Puller (201 589 01 33 00) and Thrust Piece (201 589 05 63 00), force track rod from wheel carrier.
6. Mark position of eccentric bolt of track rod in relation to axle carrier. Remove rod-to-axle carrier nut. Remove cam disk, eccentric bolt and complete track rod.
7. Remove nut of pushing strut on wheel carrier and remove with washer, contour disk and bolt. Force clamping sleeve out of wheel carrier.
8. Remove nut on spring link and remove from wheel carrier. Pull complete wheel carrier from rear axle shaft.

1. To install, reverse removal procedure. If position of eccentric bolts were not marked for pulling strut and track rod, position eccentric bolts in center position.
2. Prior to tightening any nuts axle shaft must be in horizontal position. Clean grease from ball pin and conical seat of track rod. Check toe-in and track angle of rear wheels.

Clint Hough is an author and web site publisher on imported car parts and you can get all your Mercedes Benz Parts from our on line catalog for all your Mercedes Car Parts needs at Imported car parts.com.

Tags: alternator, brakes, mercedes benz parts, pads, shocks, shoes, spark plugs, starters, strutsalternator, brakes, mercedes benz parts, pads, shocks, shoes, spark plugs, starters, struts

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