Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 213
(7) Remove plastic cover (1) (Fig. 18) by removing
screw (2) and nuts (3) and (4).
(8) Remove screws (1), (3), and (4) (Fig. 19).
(9) Remove voltage regulator (2) (Fig. 19). To pre-
vent damage to the carbon brushes, slowly pull
the voltage regulator straight out from genera-
tor without slanting or tipping.
(10) Check condition of commutator rings (1) (Fig.
20). If rings are worn, replace generator assembly.
(11) Check condition of carbon brushes (1) (Fig.
21). If brushes are worn, replace generator assembly.
Fig. 18 PLASTIC COVER
1 - Plastic Cover
2 - Screw
3 - Nut
4 - Nut
Fig. 19 MOUNTING BOLTS
1 - Screw
2 - Voltage Regulator
3 - Screw
4 - Screw
Fig. 20 COMMUTATOR RINGS
1 - Commutator Rings
Fig. 21 VOLTAGE REGULATOR
1 - Carbon Brushes
2 - Voltage Regulator
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CHARGING SYSTEM
8F - 25
INSTALLATION
(1) Check condition of carbon brushes (1) (Fig. 22).
If brushes are worn, replace generator assembly.
(2) Check condition of commutator rings (1) (Fig.
23). If rings are worn, replace generator assembly.
(3) Position voltage regulator (2) (Fig. 24) to rear
of generator. To prevent damage to the carbon
brushes (1) (Fig. 22), slowly install the voltage
regulator straight into the generator without
slanting or tipping.
(4) Install screws (1), (3), and (4) (Fig. 24).
(5) Install plastic cover (1) (Fig. 25), screw (2) and
nuts (3) and (4).
Fig. 22 VOLTAGE REGULATOR
1 - Carbon Brushes
2 - Voltage Regulator
Fig. 23 COMMUTATOR RINGS
1 - Commutator Rings
Fig. 24 MOUNTING BOLTS
1 - Screw
2 - Voltage Regulator
3 - Screw
4 - Screw
Fig. 25 PLASTIC COVER
1 - Plastic Cover
2 - Screw
3 - Nut
4 - Nut
8F - 26
CHARGING SYSTEM
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(6) Position wire eyelets (5) and (6) (Fig. 26) to
generator studs.
(7) Install + terminal nuts (3) and (4) (Fig. 26).
Tighten + nut (4) to 18 N·m (159 in. lbs.). Tighten +
nut (3) to 5 N·m (44 in. lbs.).
(8) Install turbocharger brace bolt (1) (Fig. 26) at
brace (2) (Fig. 26). Tighten bolt (1) to 20 N·m (15 ft.
lbs.).
(9) Install bolt (2) (Fig. 27) at turbocharger brace
(1) (Fig. 27). Tighten bolt (2) to 30 N·m (22 ft. lbs.).
(10) Lower vehicle.
(11) Connect negative battery cable.
(12) Check charging system for proper operation.
Fig. 26 REAR OF GENERATOR
1 - Brace Bolt
2 - Brace
3 - Nut
4 - Nut
5 - Wire
6 - Wire
Fig. 27 BRACE BOLT
1 - Turbocharger Brace
2 - Brace Bolt
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CHARGING SYSTEM
8F - 27
STARTING SYSTEM
TABLE OF CONTENTS
page
page
STARTING SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSIS AND TESTING - STARTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIFICATIONS - STARTER MOTOR -
DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . 35
STARTER MOTOR RELAY
. . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . 36
STARTING SYSTEM
DESCRIPTION
The starting system consists of:
• Starter relay
• Starter motor (including an integral starter sole-
noid)
Other components to be considered as part of start-
ing system are:
• Battery
• Battery cables
• Ignition switch and key lock cylinder
• Park/neutral position switch (automatic trans-
mission)
• Wire harnesses and connections.
The Battery, Starting, and Charging systems oper-
ate in conjunction with one another, and must be
tested as a complete system. For correct operation of
starting/charging systems, all components used in
these 3 systems must perform within specifications.
When attempting to diagnose any of these systems, it
is important that you keep their interdependency in
mind.
The diagnostic procedures used in each of these
groups include the most basic conventional diagnostic
methods, to the more sophisticated On-Board Diag-
nostics (OBD) built into the Engine Control Module
(ECM). Use of an induction-type milliampere amme-
ter, volt/ohmmeter, battery charger, carbon pile rheo-
stat (load tester), and 12-volt test lamp may be
required.
Certain starting system components are monitored
by the ECM and may produce a Diagnostic Trouble
Code (DTC).
OPERATION
The starting system components form two separate
circuits. A high-amperage feed circuit that feeds the
starter motor high-amperage, and a low-amperage
control circuit that operates on less than 20 amperes.
The high-amperage feed circuit components include
the battery, the battery cables, the contact disc por-
tion of the starter solenoid, and the starter motor
itself. The low-amperage control circuit components
include the ignition switch, the park/neutral position
switch (automatic transmission), the starter relay,
the electromagnetic windings of the starter solenoid,
and the connecting wire harness components.
If the vehicle is equipped with an automatic trans-
mission, battery voltage is supplied through the low-
amperage control circuit to the coil battery terminal
of the starter relay when the ignition switch is
turned to the momentary Start position. The park/
neutral position switch is installed in series between
the starter relay coil ground terminal and ground.
This normally open switch prevents the starter relay
from being energized and the starter motor from
operating unless the automatic transmission gear
selector is in the Neutral or Park positions.
When the starter relay coil is energized, the nor-
mally open relay contacts close. The relay contacts
connect the relay common feed terminal to the relay
normally open terminal. The closed relay contacts
energize the starter solenoid coil windings.
The energized solenoid pull-in coil pulls in the sole-
noid plunger. The solenoid plunger pulls the shift
lever in the starter motor. This engages the starter
overrunning clutch and pinion gear with the starter
ring gear on the manual transmission flywheel or on
the
automatic
transmission
torque
converter
or
torque converter drive plate.
As the solenoid plunger reaches the end of its
travel, the solenoid contact disc completes the high-
amperage starter feed circuit and energizes the sole-
noid plunger hold-in coil. Current now flows between
the solenoid battery terminal and the starter motor,
energizing the starter.
Once the engine starts, the overrunning clutch pro-
tects the starter motor from damage by allowing the
8F - 28
STARTING SYSTEM
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