IS-19905C Service Bulletin/Repair Instructions

Instruction Sheet
IS-19905C
BOSCH TO DELCO REMY ALTERNATOR INSTALLATION, H3-45 WITH

ELECTRIC FAN DRIVE

From K-0185

Revision C
Kit 0610108, removed 560629, added 0610187. Modified instructions.
2019-04-16
MATERIAL

Order Main Kit IS19905, which contains

Part No.
Description
Qty
0610086
Alternator Mechanical Kit, Right
1
0610087
Alternator Mechanical Kit, Left
1
0610089
Adaptation Kit, Right, H345
1
0610090
Adaptation Kit, Left, H345
1
0610108
Boost Regulator Kit, EFD
1
IS-19905
Instruction Sheet
1
FI-19905
Feuille d’instructions
1
0610086 Alternator Mechanical Kit, Right

Part No.
Description
Qty
560720
Alternator Remy 55SI 24V-250A Pad Mount
1
069892
Pulley 8PK, 83 DOB
1
069894
Bracket, Alternator Remy
1
506065
Belt Poly V 8PK1435 EPDM QT+Aramide
2
5001308
SCREW CAP HEXF N500 M10-1.5X40 G10.9
4
5002091
SCREW CAP HEXF N500 M10-1.5X120 G10.9
4
5001137
WASHER FL SS .203X.438X.06 (M5,#10)
2
5001180
NUT HEX NYRT SS 10-24
2
500411
WASHER FL SS .260X.697X.05 (M6,1/4)
1
5001341
WASHER FL SS 8.4X17X1.6 (M8,5/16)
1
500685
NUT HEX NYRT 5/16-18 SS
1
Writer: FL
IS-19905C

Page 2 / 45
0610087 Alternator Mechanical Kit, Left

Part No.
Description
Qty
560720
Alternator Remy 55SI 24V-250A PadMount
1
069893
Pulley 10PK, 69 DOB
1
010090
LH alternator engine support
1
069890
Bracket, Alternator Remy LH lower
1
069891
Bracket, Alternator Remy LH upper
1
061502
Cable support transition
1
010111
Decal, M4 Mot Belts FES
1
506067
Belt Poly V 10PK1703 EPDM QT+ Aramide *1
2
5001308
SCREW CAP HEXF N500 M10-1.5X40 G10.9
4
5002091
SCREW CAP HEXF N500 M10-1.5X120 G10.9
4
5001137
WASHER FL SS .203X.438X.06 (M5,#10)
2
5001180
NUT HEX NYRT SS 10-24
2
500411
WASHER FL SS .260X.697X.05 (M6,1/4)
1
5001341
WASHER FL SS 8.4X17X1.6 (M8,5/16)
1
500685
NUT HEX NYRT 5/16-18 SS
1
504379
RIVET POP DOME OE 3/16x1/4 SS
6
0610037
Control wiring harness LH alternator
1
0610035
Ground cable LH alternator
1
Writer: FL
IS-19905C

Page 3 / 45
0610089 Adaptation Kit, Right, H345

Part No.
Description
Qty

1
450580
MODIFIED BRACE, AC COMPRESSOR
5000360
STUD, M10-1.5X52 N500
5001834
WASHER BEL SPR 10.5X23X2.5 N500
1
5001930
NUT HEXF NYRT M10-1.5 N500 G10.9
1
N55439-02
RING TERMINAL 5MM / 16-14 / DURASEAL
3
N33509-06
Shrink tubing
1
12”
0610052
Power cable RH alternator H345
1
0610034
Ground cable RH alternator
1
0610090 Adaptation Kit, Left, H345

Part No.

0610053
Description

Power cable LH alternator H345
Qty

1
0610108 Boost Regulator Kit, EFD

Part No.
Description
Qty
0610001
Support Boost Regulator
1
0610187
Boost Regulator Jumper
1
5001975
SCR TC BDG PH SS410 Z050 10-24X3/8
4
5001137
WSH FL SS .203X.438X.06 (M5,#10)
3
0610042
Boost regulator harness
1
0610036
Control wiring harness RH alternator
1
Other parts not provided in the kit; shop supplies

Part No.
Description
Qty
504016
CABLE TIE, 5/16" X 14"1/2
A/R
507664
CABLE TIE, DOUBLE LOOP
A/R
509491
CABLE TIE, WIDE 13MM x 383MM
A/R
Writer: FL
IS-19905C

Page 4 / 45
504637
CABLE TIE / 3/16" x 13"
A/R
684013
COLOR GUARD RUBBER COATING, 14.5 OZ CAN
A/R
680038
LOCTITE 243, BLUE,50ml
A/R
680100
LOCTITE 271, RED, 250ml
A/R
Brake cleaner
A/R
-
Writer: FL
IS-19905C

Page 5 / 45
TOOLS

15/16”

THIN

CROWFOOT
WALL

ADAPTER.
680888 CLUTCH EXTRACTOR
Extractor tool Prevost 682256

VECR
Deutsch extractor

682321 C397
Prevost
Extractor tool Prevost 568103

IOEB
RATCHET AND SOCKET SET

– METRIC
HEX BIT

METRIC
SET
METRIC OPEN END WRENCH

SET
SOFT FACED HAMMER
1 5/8 OPEN END WRENCH
TORQUE WRENCH
½ SQUARE DRIVE BREAKER

BAR
VOLTMETER / MULTIMETER
BELT TENSION GAUGE
RIVETER
SOCKET
–
CUTTING PLIERS
Writer: FL
IS-19905C

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 ........................................................................................................21

BOSCH ALTERNATOR REMOVAL, LEFT HAND SIDE ..............................................................................................24

LEFT HAND ALTERNATOR INSTALLATION ...........................................................................................................30

LEFT HAND ALTERNATOR CONNECTIONS ...........................................................................................................36

MAIN POWER COMPARTMENT CONNECTIONS ‐ H SERIES‐ EFD ..........................................................................39

MULTIPLEX PROGRAMMING .............................................................................................................................42

FUNCTIONAL TESTING .......................................................................................................................................42

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-19905C

Page 7 / 45
ELECTRICAL SCHEMATICS
FIGURE 1: ALTERNATOR CONNECTIONS W/ HARNESS NUMBERS
FIGURE 2: POWER CABLE CONNECTIONS IN MAIN POWER COMPARTMENT
Writer: FL
IS-19905C

Page 8 / 45
FIGURE 3: 0610042 & 0610187 HARNESS CONNECTIONS IN MAIN POWER COMPARTMENT
Writer: FL
IS-19905C

Page 9 / 45
CONNECTOR PINOUT REFERENCE
FIGURE 4: IOEB PINOUT
FIGURE 5: VECR TYPICAL PINOUT

12 3

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