im
rel

9

on
i
s
r

1

3
an

J

01
2
,

ve

P

FIGURE 4

Writer: fl

IS-19907
Page 8 / 14

4.

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

FIGURE 5

5.

Installing the alternator pulley.

9

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.
ary

in

on
i
s
r

1

3
an

J

01
2
,

ve

m
Slide pulley 069892 on shaft bylihand.
re

P snug.
Hand thread nut on shaft until

Using 15/16”adapter and 8mm hex bit to
block shaft rotation, tighten to 70-80 lb-ft.
Apply torque seal
Never use power tools to install pulley and
nut.

FIGURE 6

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

Writer: fl

IS-19907
Page 9 / 14

6.

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

FIGURE 7

7.

Install alternator on engine with four (4)
5002091 M10x120 bolts.

9

Apply blue Loctite 680038
Tighten to 48 lb-ft

on
i
s
r

Apply torque seal.

in

ary

im
rel

1

3
an

J

01
2
,

ve

P

FIGURE 8

Writer: fl

IS-19907
Page 10 / 14

ALTERNATOR CONNECTIONS
8.

Locate the former Bosch alternator connectors G03 and G02.
Some wires will be used on the new installation. The other wires should be sealed with double
wall heat shrink. Refer to ELECTRICAL SCHEMATICS.

Original Connector : Pin

Wire

Action

G02:2

A03.C7DA

Cut; Crimp 560082 ring terminal together with
wire A03.C14DA using 560082

G02:3

F18DA

Cut; Crimp 560082 ring terminal

G02:4

R4

Cut; Heat shrink seal

G03:2

A03.C14DA

Cut; See G02:2 Crimp along with A03.C7DA

G03:3

F18DA

Cut; Crimp 560082 ring terminal.

G03:4

R4

Cut; Heat shrink seal

9

9.

Refer to ELECTRICAL SCHEMATICS.
Connect F18DA to Sense.

J

e

v
Connect A03.C7DA/A03.C14DA to Indicator.
ry
a

on
i
s
r

1

3
an

Connect control wires.

01
2
,

n
Use 5001180 10-24 Nylon lock
minuts and
i
l
5001137 washers.
re
P

Tighten to the following torque values:
Sense: 25-45 lb-in (3.0 5.0 N-m)
Indicator: 25-45 lb-in (3.0 5.0 N-m)
Apply color guard 684013 on connections.

FIGURE 9

Writer: fl

IS-19907
Page 11 / 14

10. Install power cable on alternator. Reuse the
existing cable. (Figure 61)
Use 500685, 5/16-18 nylon lock nut and
5001341, 8.4x17.0x1.6 SS washer.
Tighten to 80-125 lb-in (9.0-14.0 N-m)
Apply
color
connections.

guard

684013

on

FIGURE 10

11. Prepare the alternator belt tensioner bracket
012656 by creating a relief on the back of
the tensioner mounting pad to clear the
alternator fan.
See image for dimensions.
Aim for a smooth surface finish and contour.

9

in

ary

im
rel

on
i
s
r

1

3
an

J

01
2
,

ve

P

FIGURE 11

Writer: fl

IS-19907
Page 12 / 14

12. Install bracket on engine.
A: 500796, M8-1.25x50: 22 lb-ft
B: 5001801, M10-1.5x55 (2x): 43 lb-ft

FIGURE 12

9

on
i
s
r

1

3
an

J

01
2
,

FIGURE 13

13. Install ground cable on alternator upper
ve
ground pad. Reuse the existing cable.ary

in

m
Add 500411.260x.697x.050 SSliwasher.
re

P N-m)
Ground: 50-60 lb-in (5.6-6.8

Apply color guard 684013 on connections.

FIGURE 14

Writer: fl

IS-19907
Page 13 / 14

14. Place ground
bracket.

cable

on

the

tensioner

Tighten to 240 lb-in.
Apply color guard 684013 on connections.

FIGURE 15

15. Install the alternator belt tensioner with
hardware reserved earlier.
Tighten to 48 lb-ft.
Apply torque seal

9

in

ary

im
rel

on
i
s
r

1

3
an

J

01
2
,

ve

P

FIGURE 16

16. Install alternator belt. To do so, rotate the
automatic belt tensioner using a ½ square
drive breaker bar

FIGURE 17

Writer: fl

IS-19907
Page 14 / 14

FUNCTIONAL TESTING
17. Reset main circuit breakers if applicable. Set the battery master switch (master cut-out) to the ON
position and start the engine. Make sure that the charging system is working normally.
On the instruments cluster, the alternator telltale

illuminates if the alternators are not charging.

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

FUNCTIONAL TESTING

0.5h

PARTS / WASTE DISPOSAL

im
rel

in

ary

on
i
s
r

J

3
an

1

19
0
,2

Total

3.5 hours

ve

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

Writer: fl