MAINTENANCE
INFORMATION
DATE :
JUNE 2014
SUBJECT : BOSCH HD10
INSTALLATION
REVISION A

MI14-40A
SECTION : 06 - Electrical
ALTERNATOR REMOVAL &

THIS REVISION SUPERSEDES THE PREVIOUS VERSION.
Alternator pulley flanged nut torque was 58 lbf-ft, changed for 75 lbf-ft.

APPLICATION
Model

VIN

APPLICABLE TO:
X3-45 Commuter
Model Year : From 2012

DOB Bus Number Series 2400 - 2489
DOB Bus Number Series 2490 - 2789

MATERIAL
Parts and product that might be required:
Part No.

Description

Qty

502573

WASHER, FLAT M6 STAINLESS STEEL

2

564590

ADAPTER

1

5001182

NUT, M6 STAINLESS STEEL

2

5001341

WASHER, FLAT M8 STAINLESS STEEL

3

5001787

NUT, M8 STAINLESS STEEL

2

Part No.
684013

Description
COLOR GUARD RUBBER COATING, 14.5 OZ CAN

MI14-40A / Page 2 / 9

REQUIRED TOOLS
RATCHET AND SOCKET SET - METRIC

TORQUE WRENCH

SPECIAL TOOLS REQUIRED TO TIGHTEN THE ALTERNATOR PULLEY MOUNTING NUT

METRIC 10mm 12-POINTS SPLINE DRIVE LONG (CARLYLE SLTS3810M AVAILABLE FROM NAPA )

OFFSET 7/8 WRENCH (CYLINDER HEAD WRENCH), SNAP-ON PART
NUMBER M4201

7/8 SOCKET (PART NUMBER WA2828A)

OFFSET 7/8 WRENCH FITTED WITH 7/8 SOCKET AND 10mm 12-POINTS
SPLINE DRIVE

MI14-40A / Page 3 / 9

USING THE CYLINDER HEAD WRENCH
RATCHET AND A FLEX SOCKET WRENCH

WITH

A

PROCEDURE

DANGER
Park vehicle safely, apply parking brake, stop engine. In the battery box, set the battery cut-off switch
to the OFF position prior to working on the vehicle.

1. Remove the A/C compressor belts and then
remove A/C compressor idler pulley bracket
assembly (3 bolts to be removed, figure 1).

FIGURE 1

MI14-40A / Page 4 / 9

2. Remove the alternator belt (figure 2).
3. Unscrew the alternator pulley mounting nut
(figure 2).
4. Remove the alternator pulley (2 pulleys) (figure
2).

FIGURE 2

5. Remove the existing alternators. To do so,
unscrew identified mounting bolts on figure 3.
6. Identify alternator cables and then disconnect
cables. Properly clean alternator stud terminals
and cable ring terminals.

FIGURE 3

MI14-40A / Page 5 / 9

7. Install new alternators. Fix lower and upper
alternators loosely to alternator supports using
bolts C. Also, mount arched support loosely
onto alternators using bolts B. If applicable,
install stone guard. Use Loctite 243 blue on
threads (figure 4).
8. In order to assure proper installation, it is
important to tighten the alternator mounting
bolts in proper sequence. Use Loctite 243 blue
on threads (figure 4).
1st Bolt/Nut B, 43 lbf-ft (2x).
2nd Bolt/Nut C, 74 lbf-ft (2x).
For reference:
C= nut M12 #5001728
B= nut M10 #5001727

FIGURE 4

9. Mount pulley onto alternators (figure 5). Use
Loctite 243 blue on threads. Tighten pulley
mounting nut to 75 lbf-ft using offset 7/8
wrench and a M10 12-points spline drive
mounted on a torque wrench (refer to
REQUIRED TOOLS for details concerning
special tools).

FIGURE 5

10. Install the alternator belt (figure 6)

FIGURE 6

MI14-40A / Page 6 / 9

11. Cable connection overview. Upper and lower
alternator (figure 7).

FIGURE 7

UPPER ALTERNATOR - (use new hardware for cable connection)
12. Power harness and jumper cable.
a) Install jumper cable (a.k.a. positive cable) onto B1+ stud terminal on upper alternator (figure 8).
b) Place one new flat washer #5001341 against the jumper cable ring terminal (figure 8).
c) Screw and tighten the adapter stud #564590 (torque: 10 lbf-ft) (figure 8) prior installing main
battery cable (power cable).
d) Fit the main battery cable onto adaptor stud, place one new flat washer #5001341 against the
battery cable terminal and screw a new nut #5001787 (nut torque: 10 lbf-ft) (figure 8).

FIGURE 8 : STEP 12 a, b, c, d

MI14-40A / Page 7 / 9

13. Fit the ground cable onto the alternator ground stud, place one new flat washer #502573 against the
ground cable terminal and screw a new nut #5001182 (nut torque: 6 lbf-ft) (figure 8).
14. Plug alternator harness onto upper alternator connector and secure using nylon cable ties (figure 9).

FIGURE 9

MI14-40A / Page 8 / 9

LOWER ALTERNATOR - (use new hardware for cable connection)
15. Jumper cable (positive cable) installation.
a) Fit jumper cable (a.k.a. positive cable) onto B1+ stud terminal on lower alternator (figures 7 &
10).
b) Place one new flat washer #5001341 against the jumper cable ring terminal and screw new nut
#5001787 (nut torque: 10 lbf-ft) (figure 10).
16. Fit the ground cable onto the alternator ground stud, place one new flat washer #502573 against the
ground cable ring terminal and screw a new nut #5001182 (nut torque: 6 lbf-ft) (figure 10).

FIGURE 10

17. Plug alternator harness onto lower
alternator connector and secure
using two nylon cable ties #504637
(figure 11).

FIGURE 11

MI14-40A / Page 9 / 9

18. Apply anti-corrosion compound on alternator terminals and cable ring terminals or use color guard
rubber coating #684013 if available.
19. Reinstall the A/C compressor idler pulley bracket assembly (figure 12). Apply Loctite 243 on
threads. Reinstall the A/C compressor belts.

FIGURE 12

20. Finally, check that all cables are properly installed, start engine and check for proper functioning.
Check for proper functioning of charging system.

PARTS / WASTE DISPOSAL
Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)

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