Charging 2001-04 PDF

2001-04 STARTING & CHARGING SYSTEMS
Generators & Regulators - 170.465 & 170.466 Chassis

IDENTIFICATION
CHASSIS & ENGINE IDENTIFICATION
DESCRIPTION
Bosch generators are available in various amp ratings depending on engine application. Voltage regulators are
transistorized and internal to generator. See GENERATOR APPLICATION table.
GENERATOR APPLICATION
ADJUSTMENTS
DRIVE BELT ROUTING
WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, see SERVICE PRECAUTIONS (or AIR BAG SAFETY
PRECAUTIONS) and DISABLING & ACTIVATING AIR BAG SYSTEM in
appropriate AIR BAG RESTRAINT SYSTEMS article.
NOTE: When the battery is disconnected, vehicle computer and memory system may
lose data. Driveability problems may exist until computer systems have
completed a relearn cycle.
Model (Year) Chassis Engine
SLK32 AMG (2002-04) 170.466 112.960
SLK320 (2001-04) 170.465 112.947
Application Amp Rating
V6 120
NOTE: Vehicles have automatic belt tensioners. No adjustment is necessary.
NOTE: For drive belt routing, see Fig. 1 .

2003 Mercedes-Benz SLK320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 170.465 & 170.466 Chassis

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Friday, October 30, 2009 8:09:27 AM Page 1 2005 Mitchell Repair Information Company, LLC.
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Fig. 1: Drive Belt Routing
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TROUBLE SHOOTING
PRELIMINARY INSPECTION
Verify customer complaint by operating system. Visually inspect for obvious signs of mechanical and electrical
damage. Check generator belt tension and condition. Ensure that battery voltage is within specifications. Inspect
for blown fuses and damaged relays.
Verify ground connection integrity between engine, body, battery and generator. Check for damaged wiring

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harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which could cause
system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure any
aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. If no fault is found,
check for conditions that might cause an intermittent situation.
SERVICE PRECAUTIONS
BATTERY DISCONNECT/CONNECT
Disconnect/Connect Procedures
1. Turn off ignition. Open engine hood. After opening vehicle wait at least 4 minutes before disconnecting
battery or alarm will be triggered.
2. Connect quiescent current retention unit, if necessary.
3. Disconnect negative battery cable (1) and insulate cable lug to prevent unwanted contact with ground
point (W16/4). See Fig. 2 .
4. To connect, reverse disconnect procedure.
5. If quiescent current retention unit was not used, perform basic programming. See BASIC
PROGRAMMING . Using appropriate scan tool, retrieve and erase any DTCs stored in memory. See
RETRIEVING & ERASING DIAGNOSTIC TROUBLE CODES .
NOTE: Numbers and letters in text refer to numbers and letters in figures.

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Fig. 2: Disconnecting Negative Battery Cable
BASIC PROGRAMMING
1. Code radio. See CODING RADIO .
2. Set time on instrument cluster. Pull out knob at lower right of speedometer. To adjust hour, turn to right.
To adjust minute, turn to left.
3. If necessary, set time at stationary heater timer.
4. Start engine and run at idle. Turn steering wheel from one lock position to the other to activate steering
angle sensor. Center steering wheel. Malfunction indicator lamp should go out.
5. If equipped, normalize tilting/sliding roof. Open sunroof and hold down switch. Sunroof moves to end
position and pulls back 1/4 turn and stops. If equipped with lemella sliding roof, close roof and keep
switch pressed for 5 to 10 seconds.
6. Normalize power windows. Completely close each window with manual switch. Hold switch in closed
position for 5 seconds.
Coding Radio

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1. Turn ignition on. CODE will appear on radio display. Enter first code number with station button. For
example, station button 1 is number 1.
2. After entering first number, CODE will disappear and first number entered will appear followed by 4
dashes. The next character to be entered flashes.
3. After entering all 5 numbers the first character starts flashing again. If an input error has occurred it can
be corrected at this time by reentering the complete correct code.
4. Press TUNE, AUTO/SEEK or SC button. If code is correct, radio automatically switches on and indicates
the station or frequency stored with station button 1. If an incorrect code number has been entered, CODE
appears again on display. If an incorrect code is entered 3 times, WAIT appears on display and radio
locks up for approximately 10 minutes. If an incorrect code is entered 3 times again, radio locks up for
approximately 10 additional minutes. After 9 incorrect attempts, lock time increases to 60 minutes.
Another 3 incorrect entries locks up radio for another 60 minutes. Radio must remain switched on during
lock up time.
TESTING
Generator malfunctions may cause a Diagnostic Trouble Codes (DTCs) to be stored in Motor Electronics
Sequential Fuel Injection (ME-SFI) system. After repairs are completed check for and erase any DTCs stored in
(ME-SFI) system. See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE. If cause of
generator malfunction is not engine performance related, replace generator.
RETRIEVING & ERASING DIAGNOSTIC TROUBLE CODES
RETRIEVING DIAGNOSTIC TROUBLE CODES
To retrieve codes using hand held tester, see Fig. 3 .
NOTE: Before replacing any component that scan tool suggests are faulty, ensure that
all wiring connections and harness connectors are okay. Ensure that power and
ground circuits are functioning properly. For circuit identification, see
appropriate WIRING DIAGRAM under ENGINE PERFORMANCE in SYSTEM
WIRING DIAGRAMS for vehicle being tested.
NOTE: For diagnostic equipment connections, see FAULT CODE DIAGNOSIS
EQUIPMENT CONNECTION .

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Fig. 3: Retrieving Codes Using Hand Held Tester
CLEARING DIAGNOSTIC TROUBLE CODES
Disconnecting vehicle battery will not erase codes. Follow scan tool equipment manufacturers instructions to
erase fault codes.
FAULT CODE DIAGNOSIS EQUIPMENT CONNECTION
To connect hand held tester scan tool to Mercedes-Benz data link connector, see Fig. 4 . To connect hand held
tester scan tool to OBD-II data link connector, see Fig. 5 .

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Fig. 4: Connecting Hand Held Tester Scan Tool To Mercedes-Benz Data Link Connector

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Fig. 5: Connecting Hand Held Tester Scan Tool To OBD-II Data Link Connector
ON-VEHICLE TESTING

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WIRING CONTINUITY
1. Connect voltmeter between generator B+terminal and ground. Voltmeter should indicate battery voltage.
If battery voltage is not indicated, check battery and check wiring between generator and battery for
corrosion, loose terminals, etc.
2. Turn ignition on and ensure instrument cluster charge indicator light (battery symbol) comes on (if
equipped). If light does not come on, check wiring between generator and warning light, including
indicator bulb. See WIRING DIAGRAMS .
GENERATOR OUTPUT
1. Ensure connections at battery and generator are clean and tight. Ensure generator, engine and body are
properly grounded. Ensure generator drive belt is properly adjusted and in good condition.
2. Connect load tester/ammeter as per tester manufacturer's instructions. See Fig. 6 . Connect voltmeter
leads to battery terminals. Start engine and run at 2200 RPM. Adjust load tester to obtain maximum
generator output. DO NOT allow voltage to drop to less than 12.7 volts.
3. Maximum generator output should be within a few amps of generator rated output (120 amp) stamped on
generator. If output is not within a few amps of generator rated output, replace voltage regulator and
retest. If output is still low, repair or replace generator.

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Fig. 6: Generator Charge Current Connection
VOLTAGE REGULATOR CONTROL
1. Connect load tester/ammeter. See Fig. 7 . Connect voltmeter leads to battery terminals. Start engine and
run at 3000 RPM until voltage stops rising. Note reading.
2. Voltage reading should be 13-14.5 volts after 2 minutes. If voltage is more than 14.5 volts, replace
voltage regulator. See VOLTAGE REGULATOR under REMOVAL & INSTALLATION. If voltage is

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less than 13 volts, inspect and repair high resistance at charging system connections.
3. If charging system connections are okay, using an oscilloscope, test diodes in generator. See DIODE
TEST . If diodes are okay, replace voltage regulator. See VOLTAGE REGULATOR under
REMOVAL & INSTALLATION. If diodes are bad, replace generator. See GENERATOR under
REMOVAL & INSTALLATION.
Fig. 7: Identifying Voltage Regulator Control Tester Connection
DIODE TEST
Connect engine tester with oscilloscope. See Fig. 8 . Start engine. Switch on low beam. Access diode test at
3000 RPM. See Fig. 9 -Fig. 11 . Replace generator as necessary.

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Fig. 8: Identifying Oscilloscope Connection For Diode Check

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Fig. 9: Identifying Oscilloscope Patterns (No Fault Indicated)

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Fig. 10: Identifying Oscilloscope Patterns (Positive Diode Defective)

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Fig. 11: Identifying Oscilloscope Patterns (Negative Diode Defective)
REMOVAL & INSTALLATION
GENERATOR
Removal & Installation
1. Disconnect and shield negative battery cable. See BATTERY DISCONNECT/CONNECT under
SERVICE PRECAUTIONS.
2. Remove "V" belt by swiveling tensioning pulley aside and holding in place with a drift. Detach lower
engine compartment paneling. Remove protection against accidental electrical contact (4). Disconnect
electrical connectors at generator. Remove bolts (3). Remove generator downward. See Fig. 12 and Fig.
13 .
NOTE: Numbers in text refer to numbers in figures.

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3. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE
SPECIFICATIONS .
Fig. 12: Removing Generator (1 Of 2)

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Fig. 13: Removing Generator (2 Of 2)
VOLTAGE REGULATOR
Removal & Installation
Compact Generator
1. Disconnect and shield negative battery cable. See BATTERY DISCONNECT/CONNECT under
SERVICE PRECAUTIONS.
NOTE: Numbers in text refer to numbers in figures.

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2. Remove generator from vehicle. See GENERATOR .
3. Remove 3 screws (1). Unclip cover (2) by pushing apart retaining lugs (3) and remove. Remove 2 screws
(4). Remove regulator (5) toward side. See Fig. 14 .
4. To install, reverse removal procedure. When inserting regulator (5), ensure ground lug (6) makes contact
with regulator.
Fig. 14: Removing Voltage Regulator (Compact Generator)
OVERHAUL
TORQUE SPECIFICATIONS
NOTE: Manufacturer does not recommend overhaul of generator.

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TORQUE SPECIFICATIONS
WIRING DIAGRAMS
Application Ft. Lbs. (N.m)
Generator Mounting Bolts 30 (42)
B+-To-Generator Nut (15)
INCH Lbs. (N.m)
D+-To-Generator Nut 35 (4)
NOTE: See CHARGING SYSTEM wiring diagram in appropriate SYSTEM WIRING
DIAGRAMS article in ELECTRICAL.

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2001-04 STARTING & CHARGING SYSTEMS

Generators & Regulators - 170.465 & 170.466 Chassis

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