MAINTENANCE
INFORMATION
DATE :
SUBJECT :

REVISION G:
Released : July 2018

FEBRUARY 2016

MI16-17G
SECTION : 06 - Electrical

BOSCH HD10 ALTERNATOR REMOVAL AND
INSTALLATION

THIS MAINTENANCE INFORMATION SUPERSEDES ALL PREVIOUS
VERSIONS.

M8 nut was part #5001787, cancelled and changed. Use M8 nut part #5001983.

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

MI16-17G / 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 /8 OPEN END WRENCH

BELT TENSION GAUGE

½ SQUARE DRIVE BREAKER BAR

voltmeter / MULTIMETER

5

CUTTING PLIERS

See “SPECIAL TOOLS REQUIRED TO TIGHTEN THE ALTERNATOR PULLEY MOUNTING NUT” in
PART 2

MI16-17G / 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

MI16-17G / 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

MI16-17G / 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

MI16-17G / 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

MI16-17G / 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

MI16-17G / 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)

MI16-17G / 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 5001983 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 5001983

torque: 11 lbf-ft

MI16-17G / 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

MI16-17G / 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)

MI16-17G / 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.