NHTSA ID Number: 10160853
Manufacturer Communication Number: IS-19906D
TSB/Document Date: 2019-06-05
Summary
This instruction sheet explains how to perform alternator conversion, from Bosch
to Delco Remy, on X3 vehicles equipped with Electric Fan Drive
Instruction Sheet
IS-19906D
BOSCH TO DELCO REMY ALTERNATOR INSTALLATION, X3-45 WITH
ELECTRIC FAN DRIVE
From H-6180 (Can)/ H-7417 (US)
Revision D
Added precisions on alternator ground hardware.
2019-05-17
MATERIAL
Order Main Kit IS19906, which contains
Part No.
Description
Qty
0610086
Alternator Mechanical Kit, Right
1
0610087
Alternator Mechanical Kit, Left
1
0610091
Adaptation Kit, Right, X3-45
1
0610107
Adaptation Kit, Left, X3-45
1
0610108
Boost Regulator Kit, EFD
1
IS-19906
Instruction Sheet
1
FI-19906
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-19906D
Page 2 / 46
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-19906D
Page 3 / 46
0610091 Adaptation Kit, Right, X345
Part No.
Description
Qty
1
450580
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
5001799
SCREW CAP HEXF M10-1.5x70 G10.9 N500
2
N55439-02
RING TERMINAL 5MM / 16-14 / INSULATED
2
N33509-06
Shrink tubing
1
12”
0610030
Power cable RH alternator X345
1
0610034
Ground cable RH alternator
1
0610107 Adaptation Kit, Left, X345
Part No.
0610031
Description
Power cable LH alternator X345
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.
504016
Writer: FL
Description
CABLE TIE, 5/16" X 14"1/2
Qty
A/R
IS-19906D
Page 4 / 46
504637
CABLE TIE / 3/16" x 13"
A/R
507664
CABLE TIE, DOUBLE LOOP
A/R
509491
CABLE TIE, WIDE 13MM x 383MM
A/R
509815
TIE MOUNT / ATTACHMENT W/FIR MOUNT
A/R
680038
LOCTITE 243, BLUE,50ml
A/R
680100
LOCTITE 271, RED, 250ml
A/R
684013
COLOR GUARD RUBBER COATING, 14.5 OZ CAN
A/R
Brake cleaner
A/R
-
Writer: FL
IS-19906D
Page 5 / 46
TOOLS
15/16”
THIN
CROWFOOT
WALL
ADAPTER.
680888 CLUTCH EXTRACTOR
Extractor tool Prevost 682256
VECR
Deutsch extractor
682321 C397
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
½ SQUARE DRIVE BREAKER
BAR
VOLTMETER / MULTIMETER
BELT TENSION GAUGE
RIVETER
–
CUTTING PLIERS
Writer: FL
IS-19906D
Page 6 / 46
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
BOSCH ALTERNATOR REMOVAL, LEFT HAND SIDE ..............................................................................................26
LEFT HAND ALTERNATOR INSTALLATION ...........................................................................................................32
LEFT HAND ALTERNATOR CONNECTIONS X3‐45 .................................................................................................38
MAIN POWER COMPARTMENT CONNECTIONS ‐ X SERIES‐ EFD ..........................................................................40
MULTIPLEX PROGRAMMING .............................................................................................................................43
FUNCTIONAL TESTING .......................................................................................................................................43
APPENDIX A – LTD WIRE GUIDELINES ................................................................................................................44
LABOR REFERENCE TABLE ..................................................................................................................................46
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-19906D
Page 7 / 46
ELECTRICAL SCHEMATICS
FIGURE 1: ALTERNATOR CONNECTIONS W/ HARNESS NUMBERS
FIGURE 2: POWER CABLE CONNECTIONS IN MAIN POWER COMPARTMENT
Writer: FL
IS-19906D
Page 8 / 46
FIGURE 3: BOOST REGULATOR / HARNESS 0610042 CONNECTIONS IN MAIN POWER COMPARTMENT
Writer: FL
IS-19906D
Page 9 / 46
CONNECTOR PINOUT REFERENCE
FIGURE 4: IOEB PINOUT
FIGURE 5: VECR TYPICAL PINOUT
FIGURE 6: C397 PINOUT
Writer: FL
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TSB/Document ID: IS-19906D
Replacement Service Bulletin Number:
MFR Communication Date: 2019-05-20
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR
MFR Component System:
MFR Component Subsystem:
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