Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 211

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

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

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

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Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 211

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