Removing Generator

Information 

• When the engine is being cleaned with high-pressure cleaning equipment, make sure that the high pressure blast is not directed directly onto the three-phase generator (risk of bearing damage). 

Information 

The pictures shown in this document may differ from the original.

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Installation position of generator

1. Vehicles with turbocharger: 

   Release hose connections on the turbocharger. To do this, pull out the locking spring -1-  on the adapter for the pressure pipe for the turbocharger. Then loosen the hose clamp -2-  on the pressure pipe at the turbocharger.

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   Releasing hose connection on turbocharger

2. Vehicles with turbocharger: 

   Pull off the pressure pipe and intake pipe on the turbocharger.

3. Vehicles with turbocharger: 

   Disconnect the connection at the charge-air cooler. To do this, remove the locking clip -1-  and pull off the line. Disconnect line -2-  for the ambient air valve. To do this, remove the spring band clamp and pull off the line.

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   Disconnecting connection on charge air cooler.

4. Vehicles with turbocharger: 

   Remove clamp -1-  on the ambient air valve and pull off the hose -2-  (-A-  ). Lift charge air hose -3-  up and remove it -B-  .

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   Removing/charge air hose

5. Vehicles with turbocharger: 

   Pull off vacuum supply hose -1-  at the ambient air valve -2-  .

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   Vacuum hose on ambient air valve

6. Loosen clamp -1-  on the coolant hose -2-  at the top of the coolant pump connection piece.

   Pull off the hose and push it to one side.

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   Right coolant hose

7. Loosen ground strap on generator.

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   Loosening ground strap

   1. 7.1  Unscrew fastening screw -1-  .
   2. 7.2  Remove ground strap -2-  from the generator -arrow-  .
8. Remove impact bracket. > Removing impact bracket 

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   Removing impact bracket

   1. 8.1  Unclip coolant return hose -1-  at the impact bracket -2-  (-A-  ).
   2. 8.2  Unclip electric line -3-  at the impact bracket -2-  (-B-  ).
   3. 8.3  Unscrew fastening screws -4-  and remove impact bracket -2-  (-C-  ).
9. Unclip line -1-  at the generator -arrow-  .

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   Unclipping line on generator

10. Unclip coolant return hose -1-  from the holder -2-  .

    Release clamp -3-  on the coolant return hose -1-  at the generator and pull off return hose.

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    Coolant return hose

11. Release clamp -1-  on the coolant supply hose -2-  and pull off the coolant supply hose.

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    Coolant supply hose

12. Remove holder for generator lines.

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    Removing holder for generator lines

    1. 12.1  Unclip electric lines for the generator and oxygen sensor at the holder -1-  (-arrows A-  ).
    2. 12.2  Unscrew fastening screw -2-  .
    3. 12.3  Open the retaining clip -3-  (-arrow B-  ) and remove the B+ line -4-  (-arrow C-  ).
    4. 12.4  Slide the holder -1-  aside -arrow D-  and leave it hanging in the vehicle.
13. Disconnect plug connection for generator.

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    Disconnecting plug connection for generator

    1. 13.1  Release plug connection for the generator -1-  (-arrow A-  ) and disconnect it -arrow B-  .
    2. 13.2  Pull plug connection for the generator -1-  along with the line bracket off the B+ line -arrow C-  .
14. Remove clamp -1-  and pull the coolant hose -2-  off the coolant pipe.

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    Disconnecting coolant hose

15. Unscrew the three fastening screws -1 and 2-  (-arrows-  ) and support the generator with your hand.

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    Unscrewing fastening screws on generator

16. Pull the generator forward.
17. Take the holder > Removing holder for generator lines  for the oxygen sensor line and generator line out of the vehicle.
18. Disconnect B+ line at the generator.

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    Disconnecting B - line at the generator

    1. 18.1  Screw off fastening nut -1-  .
    2. 18.2  Remove B+ line -2-  from the generator -arrow-  .
19. Remove the generator -1-  from the vehicle.

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    Removing generator

    1. 19.1 Protect the radiator and cylinder head from damage by covering them with a piece of cardboard, for example. 
    2. 19.2  Move the generator -1-  forward and lift it up out of the vehicle -arrow-  .