Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 212

Fig. 5 #8823 TOOL AND INA DECOUPLER

1 - INA DECOUPLER
2 - TOOL #8823 (VM.1048)

Fig. 6 END OF GENERATOR SHAFT (HEX)

1 - GENERATOR SHAFT
2 - HEX

Fig. 7 END OF GENERATOR SHAFT (SPLINED)

1 - GENERATOR SHAFT
2 - SPLINES

Fig. 8 DECOUPLER REMOVAL (INA-HEX)

1 - DEEP 10 MM SOCKET
2 - TOOL #8823 (VM.1048)

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CHARGING SYSTEM

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Litens Decoupler

(1) Disconnect negative battery cable.
(2) Remove generator and accessory drive belt.

Refer to Generator Removal.

(3) Position Special Tool #8433 (Fig. 10) into

decoupler. Align to hex end of generator shaft.

(4) 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. 11).

(5) After breaking loose with tool, unthread decou-

pler by hand from generator.

INSTALLATION

INA Decoupler

(1) Thread decoupler pulley onto generator shaft

by hand (right-hand threads).

(2) Position Special Tool #8823 (VM.1048) into

decoupler (Fig. 5).

(3) 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. 12). If splined, insert a 5/16” 6-point hex driver,
or a 10MM 12-point triple square driver into tool
#8823 (VM.1048) (Fig. 13).

Fig. 9 DECOUPLER REMOVAL (INA-SPLINED)

1 - DRIVER
2 - TOOL #8823 (VM.1048)
3 - 17 MM WRENCH

Fig. 10 # 8433 TOOL AND LITENS DECOUPLER

Fig. 11 DECOUPLER REMOVAL (LITENS)

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CHARGING SYSTEM

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(4)

Do not use an adjustable, ratcheting

“click type” torque wrench. Most “click type”
wrenches will only allow torque to be applied
in a clockwise rotation. Use a dial-type or
beam-type wrench. Tighten in counter-clockwise
rotation (Fig. 12) or, (Fig. 13). Refer to torque speci-
fications.

(5) Install accessory drive belt, and generator.

Refer to Generator Installation.

(6) Connect negative battery cable.

Litens Decoupler

(1) Thread decoupler pulley onto generator shaft

by hand (right-hand threads).

(2) Position Special Tool 8433 (Fig. 10) into decou-

pler. Align tool to hex end of generator shaft.

(3)

Do not use an adjustable, ratcheting

“click type” torque wrench. Most “click type”
wrenches will only allow torque to be applied
in a clockwise rotation. Use a dial-type or
beam-type wrench. Tighten in counter-clockwise
rotation (Fig. 14). Refer to torque specifications.

(4) Install accessory drive belt, and generator.

Refer to Generator Installation.

(5) Connect negative battery cable.

Fig. 12 DECOUPLER INSTALLATION (INA-HEX)

1 - 10MM DEEP SOCKET
2 - TOOL # 8823 (VM.1048)

Fig. 13 DECOUPLER INSTALLATION (INA SPLINED)

1 - DRIVER
2 - TOOL # 8823 (VM.1048)
3 - BACKUP WRENCH

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CHARGING SYSTEM

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VOLTAGE REGULATOR

DESCRIPTION

The electronic voltage regulator (1) (Fig. 15) is

attached to the rear of the generator. The regulator
may be serviced separately from the generator.

REMOVAL

CAUTION: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.

(1) Disconnect and isolate negative battery cable.

(2) Raise and support vehicle.

(3) Remove bolt (2) (Fig. 16) at turbocharger brace

(1) (Fig. 16).

(4) Loosen bolt (1) (Fig. 17) at brace (2) (Fig. 17).

Swivel the race (2) to the side.

(5) Remove + terminal nuts (3) and (4) (Fig. 17).
(6) Remove wires (5) and (6) (Fig. 17).

Fig. 14 DECOUPLER INSTALLATION (Litens)

Fig. 15 VOLTAGE REGULATOR

1 - Carbon Brushes
2 - Voltage Regulator

Fig. 16 BRACE BOLT

1 - Turbocharger Brace
2 - Brace Bolt

Fig. 17 REAR OF GENERATOR

1 - Brace Bolt
2 - Brace
3 - Nut
4 - Nut
5 - Wire
6 - Wire

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CHARGING SYSTEM

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