MI16-17F Service Bulletin/Repair Instructions

MAINTENANCE

INFORMATION

DATE :

SUBJECT :
REVISION F:

Released : April 2018
FEBRUARY 2016
MI16-17F

SECTION : 06 - Electrical
BOSCH HD10 ALTERNATOR REMOVAL AND

INSTALLATION
THIS MAINTENANCE INFORMATION SUPERSEDES ALL PREVIOUS

VERSIONS.
Lang electromagnetic clutch extractor/puller was #7770159, changed for #680888.
DESCRIPTION

Use this procedure for the removal and installation of the Bosch HD10 (120A or 150A) alternator.
CONTENT
REQUIRED TOOLS ................................................................................................................................................ 2

PART 1 – COLD SIDE TWIN BOSCH ALTERNATOR REMOVAL / INSTALLATION ........................................................ 3

PART 2 – PULLEY REMOVAL / INSTALLATION ..................................................................................................... 17

PART 3 – ASSEMBLY INSTRUCTIONS FOR ELECTROMAGNETIC CLUTCH – LINNIG LA16 ......................................... 20

PART 4 –HOT SIDE SINGLE BOSCH ALTERNATOR REMOVAL AND INSTALLATION ................................................. 21
MI16-17F / Page 2 / 26
REQUIRED TOOLS

METRIC OPEN END WRENCH SET
RATCHET AND SOCKET SET – METRIC
HEX BIT SOCKET SET – METRIC
TORQUE WRENCH
SOFT FACED HAMMER
1 5/8 OPEN END WRENCH
BELT TENSION GAUGE
½ SQUARE DRIVE BREAKER BAR
voltmeter / MULTIMETER
CUTTING PLIERS
See “SPECIAL TOOLS REQUIRED TO TIGHTEN THE ALTERNATOR PULLEY MOUNTING NUT” in

PART 2
MI16-17F / Page 3 / 26
PART 1 – COLD SIDE TWIN BOSCH ALTERNATOR REMOVAL / INSTALLATION
DANGER

Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition

switch to the OFF position, the battery master switch (master cut-out) to the OFF position and

trip the main circuit breakers equipped with a trip button.
RISK OF ELECTRICAL SHOCK


The alternator is connected to the batteries through master relay R1. If the ignition switch is in the

OFF position and the battery master switch (master cut-out) is set to the OFF position, there should

not be electrical power to the alternator terminals. However, a faulty master relay R1 could

eventually leave the battery power circuit closed, thus electrical power would be present at the

alternator terminals.

Using a multimeter, probe the alternator B1+ terminal and the ground terminal. Make sure that the

voltage reading is 0 volt prior disconnecting the alternator cables.
GAINING ACCESS TO THE ALTERNATORS

1. Loosen bolt A.

2. Unscrew and remove bolt B.

3. Remove the drive belt mechanical tensioner

assembly (FIGURE 2).

4. Remove the A/C compressor drive belts (2

side-by-side belts).

Note: Keep hardware for reuse
FIGURE 1
FIGURE 2
MI16-17F / Page 4 / 26
ALTERNATOR REMOVAL

5. Unscrew and remove bolt C (FIGURE 3).
FIGURE 3
6. At this point, identify the type of clutch
installed on your vehicle.
FIGURE 4
7. As an alternate way to confirm LANG type

clutch, locate “LANG” engraving on the

hub center
FIGURE 5
MI16-17F / Page 5 / 26
8.
If a LINNIG type clutch is installed, refer to

“PART 3 - ASSEMBLY INSTRUCTIONS FOR

ELECTROMAGNETIC CLUTCH – LINNIG

LA16”. Remove the Linnig clutch.
9. Remove the LANG electromagnetic clutch

assembly (FIGURE 6).
FIGURE 6
10. Hold the rotor with the 1 5/8 wrench.

Loosen and remove the M12 rotor

mounting screw with a 30mm socket.
REMOVING THE M12

SCREW
FIGURE 7
For the next step, use rotor extractor tool

#680888.

11. Screw the extractor tool into the straining

washer only until the rotor pops off the

tapered shaft. Then work the rotor off the

shaft by hand with help from soft faced

mallet as needed.

PULL OFF THE ROTOR WITH

TOOL #680888 (shown)
TAKE OFF THE ROTOR

FIGURE 8
12. Loosen the fastening screws (4x) of the coil

and pull the coil off the retainer.
FIGURE 9
MI16-17F / Page 6 / 26
13. Unscrew and remove two socket cap screws E

(FIGURE 10).

14. Put the reinforcement bracket aside.
FIGURE 10
15. Remove the alternator drive belt. To do so,

rotate the automatic belt tensioner using a ½

square drive breaker bar.

16. Remove the alternator belt tensioner bracket

assembly. To do so, remove the three bolts

identified with arrows on FIGURE 11.

17. Put the alternator drive belt aside.
FIGURE 11
18. Disconnect the alternator cables. Properly

clean cable ring terminals as applicable using

a brass wire cup brush, a Scotch-Brite pad or

an emery cloth.

Keep hardware for reuse.
FIGURE 12

A: (+) POWER CABLE

B: (+) JUMPER CABLE

C: ALTERNATOR HARNESS

D: GROUND CABLE
MI16-17F / Page 7 / 26
19. Remove the existing alternators. To do so,

unscrew the four (4) mounting bolts identified

on FIGURE 13.

Keep hardware for reuse.
FIGURE 13
MI16-17F / Page 8 / 26
ALTERNATOR INSTALLATION

20. Apply anti-seize compound (Prevost p/n:

680335) inside the alternator mounting ears

(FIGURE 14) and inside the sleeves on the

alternator support (FIGURE 15).
FIGURE 14
FIGURE 15
21. Install the alternators. Fix lower and upper

alternators loosely to alternator supports using

bolts C. Also, mount arched support loosely

onto alternators using bolts B (FIGURE 16).

Use Loctite 243 Blue on threads.

NOTE: Reuse existing bolts unless they are

not in good condition (damaged, pitted,

eroded).

For reference:

C= NUT M12 p/n 5001761 (2X)

C= BOLT M12x160 p/n 5001853 (2X)

B= NUT M10 p/n 5001930 (2X)
FIGURE 16
B= BOLT M10x45 p/n 5001800 (2X)
MI16-17F / Page 9 / 26
22. In order to assure proper installation, it is

important to tighten the alternator mounting

bolts in proper sequence (FIGURE 17).

Tighten bolt B first, then finish with bolt C
FIGURE 17

B: torque 48 lbf-ft

C: torque 82 lbf-ft
23. Connect jumper cable B to B1+ stud terminal

of the upper alternator and the lower alternator

using hardware shown on FIGURE 18.

a) Install jumper cable B onto B1+ stud

terminal on upper alternator.

b) Place one flat washer D against the jumper

cable lug.

c) Screw and tighten the adapter stud C.

d) Fit jumper cable B onto B1+ stud terminal

on lower alternator.

e) Place one flat washer D against the jumper

cable B lug and screw nut E.

FIGURE 18

B : JUMPER CABLE p/n 067835

C : STUD ADAPTER p/n 060297 torque: 11 lbf-ft

D: FLAT WASHER p/n 5001341

E: NUT M8 p/n 5001787 torque: 11 lbf-ft
24. Reinstall the (+) power cable A. To do so,

connect power cable A to the upper alternator

B1+ stud terminal. Refer to FIGURE 19.

a) Fit the (+) power cable lug onto adaptor

stud, place one flat washer D against the

power cable terminal and screw nut E.
FIGURE 19

A: (+) POWER CABLE

D: FLAT WASHER P/N 5001341

E: NUT M8 P/N 5001787
torque: 11 lbf-ft
MI16-17F / Page 10 / 26
25. Fit the ground cables onto their respective

alternator ground studs. For each alternator,

place one flat washer F against the ground

cable lug and screw nut G.
FIGURE 20

F: FLAT WASHER P/N 502573

G: NUT M6 P/N 5001182
torque: 6 lbf-ft
H : GROUND CABLES
26. On the upper alternator, plug alternator

harness onto alternator connector and secure

using nylon cable ties P/N 504637 positioned

as shown by red arrows on FIGURE 21.

NOTE: one nylon tie is used to block the

connector locking mechanism in order to

prevent

unwanted

unlocking

and

disconnection.
FIGURE 21
27. On the lower alternator, plug alternator

harness onto alternator connector and secure

using nylon cable ties P/N 504637 positioned

as shown by red arrows on FIGURE 22.

NOTE: one nylon tie is used to block the

connector locking mechanism in order to

prevent unwanted unlocking and disconnection
FIGURE 22
MI16-17F / Page 11 / 26
28.
Apply anti-corrosion compound or Color Guard Rubber Coating (Prevost p/n: 684013) on

alternator terminals, cable lugs and nuts.
29. Mount the alternator belt tensioner bracket

assembly loosely using previously removed

bolts I & J (FIGURE 23).
FIGURE 23

I: SCREW CAP HEXF M8-1.25X50 G10.9 p/n 500796 qty.1

J: SCREW CAP HEXF M10-1.25X55 G10.9 p/n 5001801 qty.2
30. Install the reinforcement bracket. Use two

previously removed cap screws E and flat

washers. DO NOT apply final torque at this

moment.

Note: Use blue Loctite 243 on threads.

Note: Once thread locker is applied, do not

wait too long before applying final torque.

Final tightening will be done in the next

following steps.

Cap screw E according to clutch type

Lang clutch screw E p/n 5001616

Torque 40 lbf-ft (54 N-m)

FIGURE 24
LINNIG clutch screw E p/n 502949

Torque 32 lbf-ft (43 N-m)
MI16-17F / Page 12 / 26
31. Continue with the installation of the

reinforcement bracket as shown using

previously removed hardware (bolt C finger

tightened and flat washer). DO NOT apply

final torque at this moment.

Note: Use Blue Loctite 243 on threads.

Note: Once thread locker is applied, do not

wait too long before applying final torque.

FIGURE 25
32. If bolts C & E (see two previous steps) are

difficult to align in the hole, the compressor

may be moved. Loosen the compressor

mounting bolts (4x) at the base (see FIGURE

26
STREET SIDE

COMPRESSOR MOUNTING

BOLTS
CURBSIDE COMPRESSOR

MOUNTING BOLTS

FIGURE 26
33. Snug bolts C & E (FIGURE 24 & FIGURE 25).

34. Snug compressor mounting bolts at the base.

35. Snug bolts I & J indicated with arrows on

FIGURE 27.

Note: Use blue Loctite 243 on threads.
36. Tighten the compressor mounting bolts to 74

lbf-ft. (100 N-m).

FIGURE 27
37. Tighten the three bolts shown on FIGURE 28 to

prescribed torque.
FIGURE 28

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