Remove and install generator

AR15.40-P-5032IB

Remove and install generator

14.2.12

 

Remove/install

Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect ground cable of battery

 Do not connect quiescent current retention device!

AR54.10-P-0003I



Battery notes

All models

AH54.10-P-0001-01A

2

Remove bottom parts of noise encapsulation at front and in middle

Danger!

Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles.

Wear protective gloves, protective clothing and eye protection.

AS20.00-Z-0001-01A

3

Drain coolant

AR20.00-P-1142HB

4

Remove right trim panel of cylinder head cover

5

Remove air intake pipes (1, 2)

6

Remove fan shroud (3).

AR20.40-P-6800M

7

Remove poly V-belt

AR13.22-P-1202HB

8

Remove hose (4)

9

Remove charge air pipe (5) and charge air hose from turbocharger to charge air cooler

 Installation: Use new sealing rings.

AR09.41-P-1311M

10

Remove coolant hoses (6, 7) and pipe (8)

11

Unscrew bolt of coolant line (9) at crankcase and remove coolant line

 Installation: Use new O-rings.

12

Unbolt transmission oil line (10) at radiator

13

Separate coupling (11)

 Remove cable strap, if fitted.

14

Disconnect electric cable of circuit 30 (12)



*BA15.40-P-1002-01D

15

Unscrew bolts (13) of generator housing (14)



 The bottom two bolts are accessible between front axle carrier and oil pan.

*BA15.40-P-1006-01D

16

Lift generator (G2) up and out complete with generator housing

 Installation: Fit new seal onto generator housing and ensure correctly installed.

17

Install in the reverse order

18

Inspect cooling system for leaks

AR20.00-P-1010HA

19

Carry out functional test

20

Make electrical system ready for operation

 Carry out basic programming.

AR00.19-P-0200M

Number

Designation

Engine
613

BA15.40-P-1002-01D

Nut, terminal B+ to generator

NM

15

BA15.40-P-1006-01D

Bolt of cooler housing of generator to crankcase

M7

NM

14

M8

NM

20