How to Replace an Overrunning Alternator Pulley - Mercedes C/CLK/E Class

In this video, I show you how to replace the alternator pulley, on a Mercedes. The car in the video is a Mercedes CLK (W209 2002-2009), but the process is the same for all Mercedes vehicles that have an OM646 diesel engine (200/220 CDI). This includes the C Class (W203), E-Class (W211), CLC Class (W203), and any car that has a clutched/overrunning alternator pulley. The alternator pulley can fail, causing the tensioner to bounce around due to increased resistance.
Tools used:
- 17mm 12 point deep/swan neck spanner
- 1/2 inch drive breaker bar or 1/2 inch drive ratchet
- Blue Print ADG05506 Freewheel pulley tool - this is an M10 spline bit, with a 33 tooth bit around the outside. You can purchase the 33 tooth bit separately and use an M10 spline bit that you already own.
- 17mm spanner to hold the alternator tool
- Small pick or flat head screwdriver, to remove the cap from the alternator pulley
- 1/2 inch drive torque wrench
- Laser Tools 7017 Wrench Extender, to attach a torque wrench/ratchet onto a spanner
- Philips/cross head screwdriver
Note: In the video, I should have reduced the setting on the torque wrench, as the wrench extender moves the head of the torque wrench away from the pivot point - meaning the applied torque was higher than indicated. If I re-did it, I would reduce the setting to around 75-80Nm.
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[@vincemarshall8550]

hoping to do this on my fiat doblo ,taking the alternator off involves all kind of mental gymnastics ,great vid ,thanks

[@mrsinghsgarage]

Glad you found it useful:) I can imagine it was a tight squeeze to get the alternator out! Good luck for the pulley replacement.

[@vincemarshall8550]

@@mrsinghsgarage thanks mr singh x

[@konstantin-big]

What is the difference between OAP and OAD???
Can we see the difference with eyes???
Can we replace an OAP pulley with an OAD pulley????

[@Propriis.automotive]

I have a om646.811 and I belive it's the pully also was it clicking slightly at idle but as soon as you hold revs slightly higher it goes away ??

[@erdoganog]

do these pulleys make any noises before they go out or some bearing noise normal ? 70k on e300

[@mrsinghsgarage]

The idler pulleys are more common to produce noises when they're failing. The only noise that the alternator pulley will produce is a squeak when you shut off the engine.

[@toufikhaddad1094]

MerCi