Contents: Petrol models ↡ Diesel models ↡
Petrol models
Generator installation details for gasoline models
1 - Air purifier; 5 - Terminal 30 wire (B+); 6 - Terminal 61 wire (D+); 7 - Bolts; 8, 9 - Nuts; G2 - Generator; M13 - Cooling system circulation pump
1. Disconnect the negative cable from the battery.
2. Remove the air cleaner (1) (see Chapter Fuel and exhaust systems).
3. Loosen the drive belt and remove it from the generator pulley.
4. Unscrew the dipstick guide tube from the valve cover and move it to the side.
5. Remove the cooling system circulation pump (M13) installed in the wheel arch.
6. Remove the mounting bolts (7), remove the generator (G2) from the support bracket and set it aside.
7. Disconnect the electrical wiring (5, 6) and finally remove the generator (G2).
8. Installation is carried out in reverse order.
9. Finally, clear the memory of the on-board diagnostic system processor (see Section General information).
Diesel models
Models 463.323 (M612)
Generator installation details for models 463.323 (M612)
1 - Connector; 2 - Wiring of circuit 30; 3, 4, 8 - Bolts; 5 - Turbocharger oil line; 6, 7 - Coolant supply lines; G2 - Generator
1. On models with the corresponding configuration (code ET2), activate the service mode of the TELE AID emergency call system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system).
2. Connect the auxiliary battery to the standard battery.
3. Disconnect the negative cable from the battery.
4. Jack up the car and place it on supports.
5. Remove the crankcase guard.
6. Drain the cooling system (see Chapter Routine care and maintenance).
7. Remove the trim panels from the cylinder head cover.
8. Remove the air cleaner (see Chapter Fuel and exhaust systems).
9. Remove the accessory drive belt (see Chapter Engine).
10. Remove the boost system air duct.
11. Disconnect the connector (1) of the circuit 61 electrical wiring.
12. Disconnect the wiring of circuit 30 (2).
13. Unscrew the bolt (3) of the support bracket.
[Original can be found on the website: MERCEDESMAN]
14. Remove the bolt (4) and remove the coolant supply line (on the engine crankcase and turbocharger), also remove the coolant supply line (6), - prepare replacement sealing elements.
15. Remove the bolt (7) from the bracket.
16. Unscrew the mounting bolts (8) and, lowering it down, remove the generator (G2) - prepare a replacement sealing gasket to be installed between the cooling jacket flange and the engine block. If necessary, remove the drive pulley (see below).
17. Installation is carried out in the reverse order - do not forget to replace the sealing elements.
18. Deactivate the service mode of the TELE AID system and clear the memory of the processor of the on-board diagnostic system (see Section General information).
19. Finally, start the engine and check it for signs of developing coolant leaks.
Models 463.333 (M628)
Water cooled generator
Water cooled generator installation details on models 463.333 (M628)
1 - Air purifier; 2 - Air intake; 3 - Lid; 4 - Cooling system hoses; 5, 6, 9 - Screws; 7 - Electrical wiring connector; 8 - Nut for fastening terminal B+ to the generator; 10 - Support bracket; 11, 12 - Bolts; 13 - Cooler casing; G2 - Generator
1. On models with the corresponding configuration (code ET2), activate the service mode of the TELE AID emergency call system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system).
2. Disconnect the negative cable from the battery.
3. Jack up the car and place it on supports.
4. Remove the crankcase guard.
5. Drain the cooling system (see Chapter Routine care and maintenance).
6. Remove the air cleaner (1) and air intake (2) (see Chapter Fuel and exhaust systems).
7. Remove the cover (3).
8. Remove the fan shroud and the cooling system radiator (see Chapter Cooling, heating, ventilation and air conditioning systems).
9. Remove the charge air cooler (see Chapter Fuel and exhaust systems).
10. To provide access, remove the cooling system hoses (4) located in front of the generator (G2).
11. Remove the accessory drive belt (see Chapter Engine).
12. Unscrew the bolt (5) securing the cooling tract line.
13. Unscrew the bolt (6) and remove the dipstick guide tube.
14. Disconnect the electrical wiring connector (7).
15. Loosen the nut (8) securing the B+ terminal to the generator and release the electrical wiring.
16. Remove the bolt (9) securing the electrical wiring harness.
17. Unscrew the mounting bolts (11) and remove the support bracket (10) of the control module.
18. Unscrew the bolts (12) securing the cooler casing (13).
19. Press the generator (G2) together with the cooler casing (13) to the right and, pushing it forward, remove it from the engine compartment - prepare replacement sealing rings.
20. Installation is carried out in the reverse order. Check that the guide tube of the measuring probe is tightly fitted and that the air intake (2) is correctly connected to the air cleaner.
21. Finally, deactivate the service mode of the TELE AID system, clear the memory of the processor of the on-board diagnostics system (see Section General information) and check the engine for signs of developing coolant leaks.
Air cooled generator
Air-cooled generator installation details on models 463.333 (M628)
1 - Air purifier; 2 - Air intake; 3 - Lid; 4 - Cooling system hoses; 7 - Electrical wiring connector; 8 - Nut for fastening terminal B+ to the generator; 9 - Electrical wiring; 10 - Support bracket; 11, 12 - Bolts; G2 - Generator
1. On models with the corresponding configuration (code ET2), activate the service mode of the TELE AID emergency call system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system).
2. Disconnect the negative cable from the battery.
3. Jack up the car and place it on supports.
4. Remove the crankcase guard.
5. Drain the cooling system (see Chapter Routine care and maintenance).
6. Remove the air cleaner (1) and air intake (2) (see Chapter Fuel and exhaust systems).
7. Remove the cover (3).
8. Remove the fan shroud and the cooling system radiator (see Chapter Cooling, heating, ventilation and air conditioning systems).
9. Remove the charge air cooler (see Chapter Fuel and exhaust systems).
10. To provide access, remove the cooling system hoses (4) located in front of the generator (G2).
11. Remove the accessory drive belt (see Chapter Engine).
12. Disconnect the electrical wiring connector (7).
13. Loosen the nut (8) securing the B+ terminal to the generator and release the electrical wiring (9).
14. Unscrew the mounting bolts (11) and remove the bracket (10).
15. Unscrew the bolts (12) and remove the generator (G2), if necessary, remove the drive pulley (see below).
16. Installation is carried out in reverse order.
17. Finally, deactivate the service mode of the TELE AID system, clear the memory of the processor of the on-board diagnostics system (see Section General information) and check the engine for signs of developing coolant leaks.
Removal the drive pulley
Note: The generator pulley must be replaced if its mileage exceeds 100,000 km.
Generator Drive Pulley Installation Details on Diesel Models
1 - Pulley; 2 - Generator shaft; 3 - Socket head; 4 - Plug
1. Remove the generator (see above).
2. Remove the plug (4) - the plug must be replaced without fail.
3. Using a socket head (3), loosen the pulley (1), - the generator shaft (2) is held from turning using a hexagonal or serrated head.
4. Installation is carried out in reverse order.