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RIVETER

CUTTING PLIERS

Writer: fl

IS-19906
Page 6 / 45

PROCEDURE

DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position. Apply vehicle lockout
procedures according to local policies.

Table of contents
OVERVIEW ............................................................................................................................................................. 6
ELECTRICAL SCHEMATICS ....................................................................................................................................... 7
CONNECTOR PINOUT REFERENCE .......................................................................................................................... 9
BOSCH ALTERNATORS REMOVAL, RIGHT HAND SIDE ........................................................................................... 10
RIGHT HAND ALTERNATOR INSTALLATION .......................................................................................................... 15
RIGHT HAND ALTERNATOR INSTALLATION (CONTINUED) .................................................................................... 17
RIGHT HAND ALTERNATOR CONNECTIONS .......................................................................................................... 22

19

BOSCH ALTERNATOR REMOVAL, LEFT HAND SIDE ...............................................................................................
25
20

1,

3
LEFT HAND ALTERNATOR INSTALLATION .............................................................................................................
31
an

LEFT HAND ALTERNATOR CONNECTIONS X3-45 ...................................................................................................
37
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BOOST REGULATOR INSTALLATION - X SERIES- EFD v
.............................................................................................
38
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FUNCTIONAL TESTING..........................................................................................................................................
42
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P
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MULTIPLEX PROGRAMMING ...............................................................................................................................
42
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APPENDIX A – LTD WIRE GUIDELINES .................................................................................................................. 43

LABOR REFERENCE TABLE .................................................................................................................................... 45

OVERVIEW
The procedure involves removing the three existing Bosch alternators, their corresponding brackets and
harnesses and replacing them with a pair of DelcoRemy 55SI alternator.
The alternators require new brackets and harnesses. A boost regulator and corresponding harness is
also added in the main power compartment. Reprogramming the vehicles’ MUX program is required.
First time users should read the procedure before starting work on a vehicle. Best viewed in color.

Writer: fl

IS-19906
Page 7 / 45

ELECTRICAL SCHEMATICS

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FIGURE 1: ALTERNATOR CONNECTIONS W/ HARNESS NUMBERS

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FIGURE 2: POWER CABLE CONNECTIONS IN MAIN POWER COMPARTMENT

Writer: fl

IS-19906
Page 8 / 45

FIGURE 3: BOOST REGULATOR / HARNESS 0610042 CONNECTIONS IN MAIN POWER COMPARTMENT

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IS-19906
Page 9 / 45

CONNECTOR PINOUT REFERENCE

FIGURE 4: IOEB PINOUT

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FIGURE 5: VECR TYPICAL PINOUT

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FIGURE 6: C397 PINOUT

Writer: fl

IS-19906
Page 10 / 45

BOSCH ALTERNATORS REMOVAL, RIGHT HAND SIDE
1.

Loosen bolt A on A/C belt tensioner.

2.

Unscrew and remove nut B.

3.

Remove the mechanical tensioner assembly.

4.

Remove the A/C compressor drive belts (2
side-by-side belts).

Note: Keep hardware for reuse

FIGURE 7

9

5.

,

Remove the LANG electromagnetic clutch
assembly.

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FIGURE 8

6.

Hold the rotor with the 1 5/8 wrench.
Loosen and remove the M12 rotor
mounting screw.

REMOVING
SCREW

THE

M12

FIGURE 9

Writer: fl

IS-19906
Page 11 / 45

For the next step, use rotor extractor tool
#680888.
7.

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.
TAKE OFF THE ROTOR

PULL OFF THE ROTOR WITH
TOOL #680888 (shown)

8.

FIGURE 10

Loosen the fastening screws (4x) of the coil
and pull the coil off the retainer.

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FIGURE 11

Remove the support bracket
Pr mounting bolts
on the engine. Reserve.

10. Remove the belt tensioner bolt. Reserve for
re-use.
11. Remove and discard the alternator drive belt.

FIGURE 12

Writer: fl

IS-19906
Page 12 / 45

12. Unscrew and remove two socket cap screws.
13. Discard the reinforcement bracket.
14. Keep hardware for re-use.

FIGURE 13

15. Remove compressor mounting bolts and
reserve. Move compressor slightly aside to
provide working space.

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FIGURE 14

WARNING
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 before disconnecting the alternator cables.

Writer: fl

IS-19906
Page 13 / 45

16. Disconnect the Power, Jumper, Control
Harness and Ground cables from the
alternators. Discard.
17. Do not dismantle the power cable yet. This
will be done when installing the new cable.

FIGURE 15
A: (+) POWER CABLE
B: (+) JUMPER CABLE
C: CONTROL HARNESS
D: GROUND CABLE

18. Remove the existing alternators. To do so,
unscrew the four (4) mounting bolts identified
on the figure. Discard bolts and alternators.

9

19. Also remove the idler at the bottom. Discard
idler and hardware.

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FIGURE 16

Writer: fl

IS-19906
Page 14 / 45

20. Remove the alternator support bolted on the
engine. Discard support and bolts.

FIGURE 17

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Writer: fl

IS-19906
Page 15 / 45

RIGHT HAND ALTERNATOR INSTALLATION
21. Installing the alternator pulley.
Place 560720 alternator flat on a bench with
the shaft horizontal.
Required tools:
•
•

15-16” crowfoot adapter
8mm hex bit

Clean shaft and pulley with brake cleaner.
Slide pulley 069892 on shaft by hand.
Hand thread nut on shaft until snug.
Using 15/16”adapter and 8mm hex bit to
block shaft rotation, tighten to 70-80 lb-ft.
Apply torque seal
FIGURE 18

Never use power tools to install pulley and
nut.

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Note: Do not apply any pressure to end of
the shaft. Internal damage may occur if the
shaft is pushed back and turned.

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22. Install bracket 069894 on engine with four (4)
er
5001308 M10x40 bolts.
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Apply blue Loctite 680038
Tighten to 35 lb-ft.

Pr

Apply torque seal.

FIGURE 19

Writer: fl

IS-19906
Page 16 / 45

23. Install alternator on engine with four (4)