Remove/Install Integrated Starter Alternator - AR15.40-P-0003MSA

Engine 256.9 in model 213, 238, 257, 290 

Fig 1: Integrated Starter Alternator Components Location - Engine 256.9 In Model 213

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	Risk of injury  to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning  from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
Notice	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on safety-relevant components		AH00.00-Z-0019-01A
	Remove
1	Drain coolant from low-temperature circuit.		AR09.41-P-6834MSA
2	Remove transmission.		AR27.10-P-0500MSA
3	Remove starter-alternator control unit (N129).		AR15.40-P-0004MSA
4	Remove screw (6) and guide sensor connector of integrated starter-alternator (A79) through opening at timing case.	Video: Operation steps 4 to 22 are shown.	multimedia:A supplement to the article is available.
5	Remove screws (15) in reverse order to tightening procedure and remove centering flange (16).	Tightening procedure of integrated starter alternator Aid of helper required.	AR15.40-P-0003-01MRT
		Counterholder	Fig 4
6	Remove crankshaft Hall sensor (B70).		AR15.12-P-2136MSA
7	Remove screws (10) and remove coolant inlet fitting (11).
8	Remove breather connection (17).
9	Turn engine in direction of engine rotation to TDC marking (ignition TDC) of cylinder 1.	Turn engine only in the direction of engine rotation. Engine damage will occur otherwise.
		The TDC marking on the vibration damper must match with the marking on the crankcase.
		Counterholder	Fig 4
10	Install assembly tool for removal of integrated starter alternator (A79).		AR15.40-P-0003-05MRT
	Service Information: Parts identification of mounting plate for removal of integrated starter alternator in XENTRY Portal Parts Information		SI15.40-P-0012A
		Do not remove assembly tool in disassembled status from integrated starter alternator (A79). Integrated starter alternator (A79) will otherwise be damaged. Order assembly tool as a replacement part.
		Counterholder	Fig 4
11	Install support fixture.
	000 588 24 62 00 Major assembly mount		WS01.00-P-0253B
		Support fixture	Fig 2
12	Remove screws (18).
13	Remove integrated starter alternator (A79).
		Do not damage sensor connector of integrated starter alternator (A79). The function of the integrated starter alternator (A79) is otherwise not ensured.
		Integrated starter alternator (A79) must not come into contact with fluids. The function of the integrated starter alternator (A79) is otherwise not ensured.
	Install
14	Install integrated starter alternator (A79).	During insertion of integrated starter alternator (A79), ensure that sensor connector of integrated starter alternator (A79) is not damaged. The function of the integrated starter alternator (A79) is otherwise not ensured.
15	Tighten screws (18).	Bolt, stator housing to timing case	*BA15.40-P-1001-02MRT
16	Remove support fixture.
	000 588 24 62 00 Major assembly mount		WS01.00-P-0253B
		Support fixture	Fig 2
17	Remove assembly tool for removal of integrated starter alternator (A79).		AR15.40-P-0003-05MRT
		Bolt, integrated starter alternator to crankshaft	*BA15.40-P-1003-02MRT
		Bolt, stator housing to timing case	*BA15.40-P-1001-02MRT
		Counterholder	Fig 4
	Measure
18	Perform coil resistance measurement.		AR15.40-P-0003-04MRT
		Measurement of phase resistances	*BE15.40-P-1002-06MRT
	Install
19	Guide sensor connector of integrated starter alternator (A79) through opening at timing case and install with screw (6) at timing case.	Bolt, sensor connector to timing case	*BA15.40-P-1007-02MRT
20	Install centering flange (16).	Tightening procedure of integrated starter alternator Replace centering flange (16). Aid of helper required.	AR15.40-P-0003-01MRT
		Bolt, integrated starter alternator to crankshaft	*BA15.40-P-1003-02MRT
		Bolt, centering flange to crankshaft	*BA15.40-P-1002-02MRT
		Counterholder	Fig 4
21	Measure air gap between stator and rotor.		AR15.40-P-0003-03MRT
		Clearance measurement	*BE15.40-P-1001-06MRT
		Gauge If there are problems: ↓ Replace integrated starter alternator (A79).	Fig 3
22	Install starter-alternator control unit (N129).		AR15.40-P-0004MSA
23	Install crankshaft Hall sensor (B70).		AR15.12-P-2136MSA
24	Install coolant inlet fitting (11).	Bolt, coolant entry fittings to timing case	*BA15.40-P-1006-02MRT
25	Install breather connection (17).
26	Install transmission.		AR27.10-P-0500MSA
27	Add low-temperature circuit coolant.	Install lower engine compartment lining only after leak test.	AR09.41-P-6834MSA
28	Perform commissioning of starter-alternator control unit (N129).	When replacing integrated starter alternator (A79).
		Engine 256.9 in model 213	AD00.00-P-2000-04B
		Engine 256.9 in model 238	AD00.00-P-2000-06LWO
		Engine 256.9 in model 257, 290	AD00.00-P-2000-06FR
	Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
29	Carry out engine test run and check engine for proper operation and leak tightness.
30	Install lower engine compartment lining.	Engine 256.9 in model 213, 238	AR61.20-P-1105LWE
		Engine 256.9 in model 290	AR61.20-P-1105FRX
		Engine 256.9 in model 257	AR61.20-P-1105FR

TEST SPECIFICATIONS OF INTEGRATED STARTER ALTERNATOR

Number	Designation			Engine 256.9
BE15.40-P-1001-06MRT	Clearance measurement	Gap between stator and rotor	mm	0, 9

TEST SPECIFICATIONS OF INTEGRATED STARTER ALTERNATOR

Number	Designation			Engine 256
BE15.40-P-1002-06MRT	Measurement of phase resistances	Resistances of phases U-V, V-W, W-U	MΩ	9, 1 ±0, 3
		Resistances of phases X-Y, Y-Z, Z-X	MΩ	8, 7 ±0, 3
		For picture, see		AR15.40-P-0003-04MRT

STARTER-ALTERNATOR

Number	Designation			Engine 256
BA15.40-P-1001-02MRT	Bolt, stator housing to timing case	Stage 1	Nm	20
		Stage 2	∠°	60

STARTER-ALTERNATOR

Number	Designation			Engine 256
BA15.40-P-1002-02MRT	Bolt, centering flange to crankshaft	Stage 1	Nm	45
		Stage 2	∠°	90

STARTER-ALTERNATOR

Number	Designation			Engine 256
BA15.40-P-1003-02MRT	Bolt, integrated starter alternator to crankshaft	Stage 1	Nm	45
		Stage 2	∠°	90

STARTER-ALTERNATOR

Number	Designation		Engine 256
BA15.40-P-1006-02MRT	Bolt, coolant entry fittings to timing case	Nm	8

STARTER-ALTERNATOR

Number	Designation		Engine 256
BA15.40-P-1007-02MRT	Bolt, sensor connector to timing case	Nm	8

Fig 2: Identifying Support Fixture (256 589 01 31 00)

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Fig 3: Identifying Gauge (256 589 01 23 00)

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Fig 4: Identifying Counterholder (654 589 00 40 00)

Courtesy of MERCEDES-BENZ USA