Sprinter 2005-2007

Voltage Regulator

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Removal & Installation



2.7L Engine

CAUTION
Disconnect negative cable from battery before removing battery output wire from alternator. Failure to do so can result in injury.

  1. Disconnect and isolate negative battery cable.
  2.  
  3. Raise and support vehicle.
  4.  
  5. Remove bolt (2) at turbocharger brace (1).

    Click image to see an enlarged view

    Fig. Brace bolt at turbocharger brace

  6.  
  7. Loosen bolt (1) at brace (2). Swivel the race (2) to the side.

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    Fig. Loosen bolt (1) at brace (2) at rear of alternator

  8.  
  9. Remove positive (+) terminal nuts (3) and (4).
  10.  
  11. Remove wires (5) and (6).
  12.  
  13. Remove plastic cover by removing screw and nuts.
  14.  
  15. Remove screws (1), (3), and (4).

    Click image to see an enlarged view

    Fig. Remove voltage regulator

  16.  
  17. Remove voltage regulator (2). To prevent damage to the carbon brushes, slowly pull the voltage regulator straight out from alternator without slanting or tipping.
  18.  

To install:

  1. Position voltage regulator to rear of alternator. To prevent damage to the carbon brushes, slowly install the voltage regulator straight into the generator without slanting or tipping.
  2.  
  3. Install screws to attach voltage regulator.
  4.  
  5. Install plastic cover, screw and nuts.
  6.  
  7. Position wire eyelets to alternator studs.
  8.  
  9. Install positive (+) terminal nuts. Tighten positive (+) nut to 159 inch lbs. (18 N·m). Tighten smaller nut to 44 inch lbs. (5 N·m).
  10.  
  11. Install turbocharger brace bolt at brace. Tighten bolt to 15 ft. lbs. (20 N·m).
  12.  
  13. Install bolt at turbocharger brace. Tighten bolt to 22 ft. lbs. (30 N·m).
  14.  
  15. Lower vehicle.
  16.  
  17. Connect negative battery cable.
  18.  
  19. Check charging system for proper operation.
  20.  

 
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