Mercedes-Benz Sprinter / Dodge Sprinter. Service manual — part 211
CHARGING SYSTEM
TABLE OF CONTENTS
page
page
CHARGING SYSTEM
. . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . 18
GENERATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . 19
GENERATOR DECOUPLER PULLEY
. . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - GENERATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . 22
VOLTAGE REGULATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . 26
CHARGING SYSTEM
SPECIFICATIONS
TORQUE – 2.7L DIESEL
DESCRIPTION
N-m
Ft. Lbs.
In. Lbs.
B+ Terminal Nut (larger of
2 nuts)
18
-
159
D+ Terminal Nut (smaller
of 2 nuts)
5
-
44
Rear Generator Support
Bracket Bolts (to engine)
28
-
250
Generator Decoupler
110
81
-
Generator/Turbocharger
Brace Bolt at Turbocharg-
er End
30
22
-
Generator/Turbocharger
Brace Bolt at Engine End
20
15
-
VA
CHARGING SYSTEM
8F - 17
SPECIAL TOOLS
GENERATOR
DESCRIPTION
The generator is belt-driven by the engine using a
serpentine-type drive belt. It is serviced only as a
complete assembly. If the generator fails for any rea-
son, the entire assembly must be replaced.
On certain engines, the decoupler pulley may be
replaced separately.
OPERATION
As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a cur-
rent into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
provides the current needed to energize the rotor.
The stator winding connections deliver the induced
AC current to 3 positive and 3 negative diodes for
rectification. From the diodes, rectified DC current is
delivered to the vehicle electrical system through the
generator battery terminal.
Although the generators appear the same exter-
nally, different generators with different output rat-
ings are used on this vehicle. Be certain that the
replacement generator has the same output rating
and part number as the original unit. Refer to Spec-
ifications and see Generator Ratings for amperage
ratings and part numbers.
Noise emitting from the generator may be caused
by: worn, loose or defective bearings; a loose or defec-
tive drive pulley (decoupler pulley); incorrect, worn,
damaged or misadjusted fan drive belt; loose mount-
ing bolts; a misaligned drive pulley or a defective sta-
tor or diode.
An instrument panel mounted, battery charge indi-
cator lamp is used. When the key is in the on posi-
tion, the lamp will be illuminated. This is done as a
bulb check. If this lamp remains illuminated while
the engine is running, a Diagnostic Trouble Code
(DTC) has been detected for the charging system.
REMOVAL
CAUTION: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Cooling
System.
(1) Disconnect and isolate negative battery cable.
(2) Remove generator drive belt. Refer to Cooling
System for procedure.
(3) Raise and support vehicle.
(4) Remove protective plastic cover from B+ stud
at top of generator.
(5) Remove nut securing battery output cable to
B+ terminal at top of generator.
(6) Unplug field terminal connector at rear of gen-
erator.
(7) Remove 4 generator mounting bolts (Torx-style
#12 bit) (Fig. 1).
(8) Remove generator from lower side of vehicle.
GENERATOR DECOUPLER TOOL #8433
GENERATOR DECOUPLER TOOL #8823
8F - 18
CHARGING SYSTEM
VA
INSTALLATION
(1) Raise and support vehicle.
(2) Position generator to engine.
(3) Install 4 generator mounting bolts (Fig. 1).
Refer to Torque Specifications.
(4) Connect field terminal connector at rear of gen-
erator.
(5) Install battery output cable and nut to B+ ter-
minal at top of generator. Refer to Torque Specifica-
tions.
(6) Install protective plastic cover to B+ stud at
top of generator.
(7) Lower vehicle.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Cooling
System.
(8) Install generator drive belt. Refer to Cooling
System for procedure.
(9) Connect negative battery cable.
(10) Check charging system for proper operation.
GENERATOR DECOUPLER
PULLEY
DESCRIPTION
The generator decoupler is used only with
certain engines. The decoupler is used in place of
the standard generator drive pulley (Fig. 2).
OPERATION
The generator decoupler is used only with
certain engines. The decoupler (Fig. 2) is a one-way
clutch designed to help reduce belt tension fluctua-
tion, vibration, reduce fatigue loads, improve belt life,
reduce hubloads on components, and reduce noise.
Dry operation is used (no grease or lubricants). The
decoupler is not temperature sensitive and also has a
low sensitivity to electrical load. The decoupler is a
non-serviceable item and is to be replaced as an
assembly.
Fig. 1 GENERATOR MOUNTING - 2.7L DIESEL
1 - GENERATOR
2 - DRIVE BELT
3 - MOUNTING BOLTS (4)
4 - GENERATOR WIRING HARNESS
Fig. 2 GENERATOR DECOUPLER PULLEY
VA
CHARGING SYSTEM
8F - 19
DIAGNOSIS AND TESTING - GENERATOR DECOUPLER
CONDITION
POSSIBLE CAUSES
CORRECTION
Does not drive generator
(generator not charging)
Internal failure
Replace decoupler
Noise coming from decou-
pler
Internal failure
Replace decoupler
REMOVAL
The generator decoupler is used only with
certain engines.
Two different type generator decoupler pulleys are
used. One can be identified by the use of machined
splines (Fig. 3). The other can be identified by a hex
opening (Fig. 4) and will not use splines.
Different special tools are required to service each
different decoupler. Refer to following procedure.
INA Decoupler
(1) Disconnect negative battery cable.
(2) Remove generator and accessory drive belt.
Refer to Generator Removal.
(3) Position Special Tool #8823 (VM.1048) into
decoupler (Fig. 5).
(4) Determine if end of generator shaft is hex
shaped (Fig. 6) or is splined (Fig. 7). If hex is used,
insert a 10MM deep socket into tool #8823 (VM.1048)
(Fig. 8). If splined, insert a 5/16” 6-point hex driver,
or a 10MM 12-point triple square driver into tool
#8823 (VM.1048) (Fig. 9).
(5) The generator shaft uses conventional right-
hand threads to attach decoupler. To break decoupler
loose from generator threads, rotate end of tool clock-
wise (Fig. 8) or, (Fig. 9).
(6) After breaking loose with tool, unthread decou-
pler by hand from generator.
Fig. 3 GENERATOR DECOUPLER PULLEY (INA)
1 - GENERATOR
2 - DECOUPLER (INA)
3 - MACHINED SPLINES
Fig. 4 GENERATOR DECOUPLER PULLEY (LITENS)
1 - DECOUPLER (LITENS)
2 - HEX OPENING
8F - 20
CHARGING SYSTEM
VA
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