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PointedThree :  Vans, Trucks, SUVs and Other Forums : G-Class DIY Forum : Upgrading to 2002 or later G500 150A alternator

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Upgrading to 2002 or later G500 150A alternator
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Author
Posted 1/27/2011 11:31 PM
autonovice
Elite Veteran


Date registered: Dec 2006
Location: New York City
Vehicle(s): '05 G55K, '92 350GDT
Posts: 684
500
Upgrading to 2002 or later G500 150A alternator

Time to contribute ....

Thanks for fade2blk member for infos and pic.
I 've done 2 alternator upgrades using a 2002 or later 150A on my Gs (1992 and 1996).
I think it will bolt on 1990 - 2001 engines. These engines should have a serpentine belt
and not V belts.

Please correct if my infos are not correct.


===============
Find a 150A alternator. As of this posting, there are three Bosch parts that will work.
The VR may be specific to each alternator (according to this posting)

http://pointedthree.com/disc/forums/showthread.php?tid=13273&start=...

I trust fade2blk member posting on VR research for the first two altenators.
I found the last one.

MB G500/G55 Stock OEM Alternator Information : 2001-2006 (I have this ONE!)
Bosch 150AMP / 0 124 615 020
Bosch Voltage Regulator(VR) : F 00M 145 340

Newer Bosch Part :
Bosch 150AMP / 0 124 615 047
Bosch Voltage Regulator(VR) : F 00M 145 382
Needs re-clocking ... see picture below

Older Bosch Part: (I have this ONE ALSO!)
Bosch 150AMP / 0 124 615 012
Bosch Voltage Regulator(VR) : F 00M 144 138
Needs re-clocking ... see picture below


===============
Purchase special plug and pins from Mercedes dealer (should be less than $20)
Plug: A 168 545 30 28 ($)
2 Pins: A 013 545 15 26 ($$$)
Needs a molex crimper to do the right job.
I bought GC Waldom W-HT-1919-P http://ba-electronics.com/molex.htm



===============
You may want to take time out to think about upgrading your alternator to battery
cable if your alternator was a 75A. I think I used 2 gauge on mine since I had a winch.
Easiest way is to run a parallel wire from the alternator B1+ terminal to battery +.
I opt for the difficult solution which is rewired the whole right side of the engine bay!
I used westmarine marine cable, battery lug, ring terminal and a terminal insulator (for B1+)
from accidental shorting.



===============
Installation note:
1) Loosen the serpentine belt and remove the old alternator.
2) find the idiot light wire (D+) and crimp up the pin using the molex crimper and
....install to special plug. Note: the idiot light is left pin if looking at the alternator from
....the back.
3) Make sure the clocking is same as the original alternator.
4) Check the alternator pulley. The offset and diameter may be different. In this case,
....swap the pulley if the offset is different. I used an air gun so i didnt
....have to fight to keep the alternator from turning.
5) Install the new alternator and tighten serpentine belt.
6) Install the alternator to battery cable to B1+
6) I would put some silicon or heat shrink wrap to seal the back of the special plug.
7) Install special plug to alternator.



Edited by autonovice 2/3/2011 4:44 PM




(G500 Alternator Clocking - Right altenator is correct clocking.jpg)



(Special plug - Left pin is idiot light.jpg)



(Special plug pin out - left idiot - right RPM pick up.jpg)



(Special plug part number.jpg)



(Special plug.jpg)



(Special plug pin part number.jpg)



(Special plug pins.jpg)



Attachments
----------------
Attachments G500 Alternator Clocking - Right altenator is correct clocking.jpg (38KB - 1 downloads)
Attachments Special plug - Left pin is idiot light.jpg (35KB - 0 downloads)
Attachments Special plug pin out - left idiot - right RPM pick up.jpg (18KB - 1 downloads)
Attachments Special plug part number.jpg (23KB - 0 downloads)
Attachments Special plug.jpg (23KB - 0 downloads)
Attachments Special plug pin part number.jpg (32KB - 0 downloads)
Attachments Special plug pins.jpg (16KB - 0 downloads)
#183875
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Author
Posted 2/1/2011 1:54 PM
G-Wagen_enthusiast
Member


Date registered: Jun 2010
Location: Midwest
Vehicle(s): 1999 G500
Posts: 22

Re: Upgrading to 2002 or later G500 150A alternator

Thank you so much, wow what an excellent post. Thanks to this I was able to make an install correctly. One small correction - the two pin/plug deal is 013-545-15-26, in the original description listed as A 168 545 15 26 but luckily when I printed off you had a picture so I was able to figure it out.

My problem still appears to persist - a 13V at battery with engine running, I was going to run new cable per your suggestion the 2 gauge westmarine, was wondering though, on 1999 G500, does the positive terminal go straight from the B1+ of alternator DIRECTLY to the battery??? There's no regulator at all right? Just hook it up, lead under the car and connect? Correct? Thanks in advance.
#184191 - in reply to #183875
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Author
Posted 2/1/2011 5:24 PM
autonovice
Elite Veteran


Date registered: Dec 2006
Location: New York City
Vehicle(s): '05 G55K, '92 350GDT
Posts: 684
500
Re: Upgrading to 2002 or later G500 150A alternator

G-Wagen_enthusiast - 2/1/2011 10:54 AM
One small correction - the two pin/plug deal is 013-545-15-26, in the original description listed as A 168 545 15 26 but luckily when I printed off you had a picture so I was able to figure it out.


I dont understand your posting. A 013-545-15-26 will give you both pins and special plug? in one package

My dealer ordered these parts so I assume they come separately. I asked for a package deal
where I get special plug and pin in one but to no avail.
#184207 - in reply to #184191
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Author
Posted 2/1/2011 5:31 PM
autonovice
Elite Veteran


Date registered: Dec 2006
Location: New York City
Vehicle(s): '05 G55K, '92 350GDT
Posts: 684
500
Re: Upgrading to 2002 or later G500 150A alternator

G-Wagen_enthusiast - 2/1/2011 10:54 AM

My problem still appears to persist - a 13V at battery with engine running, I was going to run new cable per your suggestion the 2 gauge westmarine, was wondering though, on 1999 G500, does the positive terminal go straight from the B1+ of alternator DIRECTLY to the battery??? There's no regulator at all right? Just hook it up, lead under the car and connect? Correct? .


YES. Run cable from B1+ to positive terminal directly. On your G, the battery might be in the left rear of
the vehicle so run it to the terminal near the brake booster (some one can correct me on this)

I think you should figure out your 13v issue before tackling the extra cable run. This extra cable will help if
you have a winch or big fridge. One might run from the B1+ to the winch directly and tee off to the battery.
I ran a separate cable from B1+ to the battery and a fused cable from the battery to the winch.


Edited by autonovice 2/1/2011 5:35 PM
#184208 - in reply to #184191
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Author
Posted 2/3/2011 3:20 PM
G-Wagen_enthusiast
Member


Date registered: Jun 2010
Location: Midwest
Vehicle(s): 1999 G500
Posts: 22

Re: Upgrading to 2002 or later G500 150A alternator

Actually I DO want to get a winch, just have to work out the winch bumper details. The thing I meant by the part number is that the correct two plug part number is 013-545-15-26, as seen in the pictures, because in the original description it was listed as A 168 545 15 26 but when I printed off the entry (because it was so great, better than MB manuals) you had a picture so I was able to figure it out then. A 168 545 15 26 doesnt exist - no such part # the dealer man said. I will get the VR # tonight (hopefully). Also I thinkg its kind of ironic that your name is "autonovice" yet your status is "extreme veteran" and you're obviously no novice to the Gwagen...
#184331 - in reply to #183875
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