| Removal and Installation Dowel with a diameter of 5 mm 34 mm open-ended spanner | | -
Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
| | | -
Remove the accessory drive belt.
For additional information, refer to: Accessory Drive Belt - 1.6L Duratorq-TDCi (DV) Diesel (303-05 Accessory Drive, Removal and Installation).
| 4. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Charge air cooler outlet pipe retaining clip 3 - Charge air cooler intake pipe retaining clips 5 - Turbocharger heat shield retaining bolts 6 - Turbocharger heat shield 7 - Generator electrical connector 8 - Battery to generator cable electrical connector cap 5. To install, reverse the removal procedure. Removal Details Item 9 : Battery to generator cable | | -
Detach the battery to generator cable from the generator and position it to one side. | Item 11 : Accessory drive belt tensioner | | -
Remove the accessory drive belt tensioner.
For additional information, refer to: Accessory Drive Belt Tensioner - 1.6L Duratorq-TDCi (DV) Diesel (303-05 Accessory Drive, Removal and Installation).
| Item 13 : Generator upper front retaining bolt NOTE:Support the generator. Installation Details Item 13 : Generator upper front retaining bolt NOTE:Support the generator. | | -
Loosely install the generator upper front retaining bolt. | Item 12 : Generator lower retaining bolts | | -
Loosely install the generator lower retaining bolts. | Item 11 : Accessory drive belt tensioner | | -
- Rotate the accessory drive belt tensioner clockwise and install the dowel with a diameter of 5 mm into the hole of the accessory drive belt tensioner bracket.
| Item 10 : Generator upper rear retaining bolt | | -
Install the generator upper rear retaining bolt and tighten all the remaining generator retaining bolts. | Item 4 : Charge air cooler intake pipe NOTE:Make sure that the inside of the charge air cooler intake pipe is clean and free from any oil residue, as this will reduce the installation grip of the pipe to the turbocharger. Failure to follow this instruction may result in damage to the turbocharger. Item 2 : Charge air cooler outlet pipe NOTE:Make sure that the inside of the charge air cooler outlet pipe is clean and free from any oil residue, as this will reduce the installation grip of the pipe to the turbocharger. Failure to follow this instruction may result in damage to the turbocharger. | 
