34. Install ground cable 0610035 and power cable
0610053 on alternator.
Ground:
Add 500411 SS Washer.
Tighten to 50-60 lb-in (5.6-6.8 N-m)
Positive:
Use 5002097 Nylon lock nut and 5001341
SSWasher.
Tighten to 80-125 lb-in (9.0-14.0 N-m)
Apply color guard 684013 on connections.
35. Connect ground cable to the engine grounding
stud.
Tighten to 240 lb-in.
Apply color guard 684013 on connections.

FIGURE 69

36. Secure control cable with 504637cable ties as
indicated.

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Use one 507664 double loop cable tie secured
on the alternator grid.

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FIGURE 70

Writer: fl

IS-19905
Page 39 / 46

37. Secure ground and power cable with 504016
5/16 cable ties, as shown.

FIGURE 71

38. Route power cable up the sloped support, over
the engine and back to the main power
compartment. Connect to the 24V junction
blocks.
Tighten to 96 lb-in.
Apply torque seal.

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Refer to ELECTRICAL SCHEMATICS.

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FIGURE 72

BOOST REGULATOR INSTALLATION - H SERIES- EFD

Writer: fl

IS-19905
Page 40 / 46

39. In the main power compartment, create some
working space by unplugging and removing the
Allison transmission control module (TCM).

FIGURE 73

40. Place the boost regulator bracket 0610001 on
the top shelf.
41. If there are no existing holes on the top shelf,
drill new holes by using the bracket as a
template. Drill 4mm (5/32”) diameter holes.

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FIGURE 74

42. Install bracket 0610001 with 5001975 screws
and 5001137 washers.

FIGURE 75

Writer: fl

IS-19905
Page 41 / 46

43. Install boost regulator 560629 on bracket with
5001975 screw.

FIGURE 76

44. Plug connector C175 from harness 0610042 to
boost regulator.

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IS-19905
Page 42 / 46

1.

Before connecting the harness, locate the following components in the main electrical compartment

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FIGURE 77

2.

P

Connect 0610042 harness to the following locations in the main power compartment.
Remove existing wire in the connector cavity at these locations and replace by terminal from the
harness.
Refer to CONNECTOR PINOUT REFERENCE and Figure 3
Circuit

Device

Connector

Pin

Notes

A49J2.1

AE49

J2

1

568103 Extractor

A175J2.12

AE50

J2

8

568103 Extractor

A52J2.4

AE52

J2

4

568103 Extractor

A52J2.4

-

C397

4

682321 Extractor

A49J2.1

-

C397

67

682321 Extractor

F139

VECR

VECR4

D

682256 Extractor

00R

Electronic Ground

Term00R

Add to any stud

Tighten to 60 lb-in

Writer: fl

IS-19905
Page 43 / 46

3.

Note: Seal removed wires. Cut terminal and seal
with double wall EPS heat shrink

FIGURE 78

MULTIPLEX PROGRAMMING

9

45. In VPG, change value of parameter ALTTYP to 1. Generate program
01and transfer

2
1,
3
n
FUNCTIONAL TESTING
Ja
n
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s
r
46. Reset main circuit breakers if applicable. Set
the
battery master switch (master cut-out) to the ON
vethe charging
y
position and start the engine. Make sure
that
system is working normally.
r
na
i
lim
realternator
On the instruments cluster,P
the
telltale
illuminates if the alternators are not charging.

Writer: fl

IS-19905
Page 44 / 46

APPENDIX A – LTD WIRE GUIDELINES
IMPORTANT: It the LTD wire is disturbed; the following guidelines must be followed to secure it properly.

NOTE
Always use double loop cable ties to secure LTD. LTD must be tied alone, with no other cables in the
loop.

NOT ALLOWED

CORRECT

Possible contact or rubbing against screws,
edges, etc.

LTD must be routed clear of screws, sharp
edges, etc.

9

NOT ALLOWED

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01
2
CORRECT
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Rubbing or possible rubbing against abrasive
surfaces

LTD must be secured with double loop cable
ties. Distance between cable ties must not
exceed 4 inches (100mm) max

NOT ALLOWED

LTD touching cut cable tie

Writer: fl

IS-19905
Page 45 / 46

NOT ALLOWED

CORRECT

LTD is not a flexible harness. Avoid tight
bends and kinks which could short circuit the
LTD. Loops must hace a minimum radii of 4
inches (100 mm)

LTD extending slantingly from the cable tie

NOT ALLOWED

CORRECT

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v
ry
Cable tie tighten in excess on the n
LTD.
a
Tighten cable tie on LTD by hand
mi only.
i
l
Tighten just enough to preventreLTD from
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Proper tightening of the cable tie on the LTD

slipping from once side to the other inside
the cable tie loop

Writer: fl

IS-19905
Page 46 / 46

LABOR REFERENCE TABLE
Table for reference only.
Actual times will vary depending on vehicle condition.
Operation

Approximate
labor (hours)

Step 1

BOSCH ALTERNATORS REMOVAL, RIGHT HAND SIDE

1h

Step 2

INSTALLING THE RIGHT HAND ALTERNATOR. (includes wiring)

2h

Step 3

BOSCH ALTERNATORS REMOVAL, LEFT HAND SIDE

1h

Step 4

INSTALLING THE LEFT HAND ALTERNATOR. (includes wiring, cradle and
cable support modifications)

2.5h

Step 5

BOOST REGULATOR INSTALLATION

1.5h

Step 6

MULTIPLEX PROGRAMMING.

0.5h

Step 7

FUNCTIONAL TESTING

0.5h

9
01

Total

9 hours

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PARTS / WASTE DISPOSAL

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Discard waste according to applicable
mi environmental regulations (Municipal/State[Prov.]/ Federal)
eli

Pr

Writer: fl