MI16-17E

MAINTENANCE
INFORMATION
DATE :
SUBJECT :
REVISION E:
Released : March 2017
FEBRUARY 2016
MI16-17E
SECTION : 06 - Electrical
BOSCH HD10 ALTERNATOR REMOVAL AND
INSTALLATION
THIS MAINTENANCE INFORMATION SUPERSEDES ALL PREVIOUS
VERSIONS.
Page 19, special case for 150A alternators only, a flat washer is required when installing the pulley.
DESCRIPTION
Use this procedure for the removal and installation of the Bosch HD10 (120A or 150A) alternator.
CONTENT
REQUIRED TOOLS ................................................................................................................................................ 2
PART 1 – COLD SIDE TWIN BOSCH ALTERNATOR REMOVAL / INSTALLATION ........................................................ 3
PART 2 – PULLEY REMOVAL / INSTALLATION ..................................................................................................... 17
PART 3 – ASSEMBLY INSTRUCTIONS FOR ELECTROMAGNETIC CLUTCH – LINNIG LA16 ......................................... 20
PART 4 –HOT SIDE SINGLE BOSCH ALTERNATOR REMOVAL AND INSTALLATION ................................................. 21

MI16-17E / Page 2 / 26
REQUIRED TOOLS
METRIC OPEN END WRENCH SET
RATCHET AND SOCKET SET – METRIC
HEX BIT SOCKET SET – METRIC
TORQUE WRENCH
SOFT FACED HAMMER
1 5/8 OPEN END WRENCH
BELT TENSION GAUGE
½ SQUARE DRIVE BREAKER BAR
voltmeter / MULTIMETER
CUTTING PLIERS
See “SPECIAL TOOLS REQUIRED TO TIGHTEN THE ALTERNATOR PULLEY MOUNTING NUT” in
PART 2

MI16-17E / Page 3 / 26
PART 1 – COLD SIDE TWIN BOSCH ALTERNATOR REMOVAL / INSTALLATION
DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position, the battery master switch (master cut-out) to the OFF position and
trip the main circuit breakers equipped with a trip button.
RISK OF ELECTRICAL SHOCK

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 prior disconnecting the alternator cables.
GAINING ACCESS TO THE ALTERNATORS
1. Loosen bolt A.
2. Unscrew and remove bolt B.
3. Remove the drive belt mechanical tensioner
assembly (FIGURE 2).
4. Remove the A/C compressor drive belts (2
side-by-side belts).
Note: Keep hardware for reuse
FIGURE 1
FIGURE 2

MI16-17E / Page 4 / 26
ALTERNATOR REMOVAL
5. Unscrew and remove bolt C (FIGURE 3).
FIGURE 3
6. At this point, identify the type of clutch
installed on your vehicle.
FIGURE 4
7. As an alternate way to confirm LANG type
clutch, locate “LANG” engraving on the
hub center
FIGURE 5

MI16-17E / Page 5 / 26
8.
If a LINNIG type clutch is installed, refer to
“PART 3 - ASSEMBLY INSTRUCTIONS FOR
ELECTROMAGNETIC CLUTCH – LINNIG
LA16”. Remove the Linnig clutch.
9. Remove the LANG electromagnetic clutch
assembly (FIGURE 6).
FIGURE 6
10. Hold the rotor with the 1 5/8 wrench.
Loosen and remove the M12 rotor
mounting screw with a 30mm socket.
REMOVING THE M12
SCREW
FIGURE 7
For the next step, use rotor extractor tool
#7770159 preferably. If the tool is not
available, use a M16x50 mm hex head
bolt. (Prevost #5001372).
11. 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.
PULL OFF THE ROTOR WITH
TOOL #7770159 (shown) or
M16 BOLT
TAKE OFF THE ROTOR
FIGURE 8
12. Loosen the fastening screws (4x) of the coil
and pull the coil off the retainer.
FIGURE 9

MI16-17E / Page 6 / 26
13. Unscrew and remove two socket cap screws E
(FIGURE 10).
14. Put the reinforcement bracket aside.
FIGURE 10
15. Remove the alternator drive belt. To do so,
rotate the automatic belt tensioner using a ½
square drive breaker bar.
16. Remove the alternator belt tensioner bracket
assembly. To do so, remove the three bolts
identified with arrows on FIGURE 11.
17. Put the alternator drive belt aside.
FIGURE 11
18. Disconnect the alternator cables. Properly
clean cable ring terminals as applicable using
a brass wire cup brush, a Scotch-Brite pad or
an emery cloth.
Keep hardware for reuse.
FIGURE 12
A: (+) POWER CABLE
B: (+) JUMPER CABLE
C: ALTERNATOR HARNESS
D: GROUND CABLE

MI16-17E / Page 7 / 26
19. Remove the existing alternators. To do so,
unscrew the four (4) mounting bolts identified
on FIGURE 13.
Keep hardware for reuse.
FIGURE 13

MI16-17E / Page 8 / 26
ALTERNATOR INSTALLATION
20. Apply anti-seize compound (Prevost p/n:
680335) inside the alternator mounting ears
(FIGURE 14) and inside the sleeves on the
alternator support (FIGURE 15).
FIGURE 14
FIGURE 15
21. Install the alternators. Fix lower and upper
alternators loosely to alternator supports using
bolts C. Also, mount arched support loosely
onto alternators using bolts B (FIGURE 16).
Use Loctite 243 Blue on threads.
NOTE: Reuse existing bolts unless they are
not in good condition (damaged, pitted,
eroded).
For reference:
C= NUT M12 p/n 5001761 (2X)
C= BOLT M12x160 p/n 5001853 (2X)
B= NUT M10 p/n 5001930 (2X)
FIGURE 16
B= BOLT M10x45 p/n 5001800 (2X)

MI16-17E / Page 9 / 26
22. In order to assure proper installation, it is
important to tighten the alternator mounting
bolts in proper sequence (FIGURE 17).
Tighten bolt B first, then finish with bolt C
FIGURE 17
B: torque 48 lbf-ft
C: torque 82 lbf-ft
23. Connect jumper cable B to B1+ stud terminal
of the upper alternator and the lower alternator
using hardware shown on FIGURE 18.
a) Install jumper cable B onto B1+ stud
terminal on upper alternator.
b) Place one flat washer D against the jumper
cable lug.
c) Screw and tighten the adapter stud C.
d) Fit jumper cable B onto B1+ stud terminal
on lower alternator.
e) Place one flat washer D against the jumper
cable B lug and screw nut E.
FIGURE 18
B : JUMPER CABLE p/n 067835
C : STUD ADAPTER p/n 060297 torque: 11 lbf-ft
D: FLAT WASHER p/n 5001341
E: NUT M8 p/n 5001787 torque: 11 lbf-ft
24. Reinstall the (+) power cable A. To do so,
connect power cable A to the upper alternator
B1+ stud terminal. Refer to FIGURE 19.
a) Fit the (+) power cable lug onto adaptor
stud, place one flat washer D against the
power cable terminal and screw nut E.
FIGURE 19
A: (+) POWER CABLE
D: FLAT WASHER P/N 5001341
E: NUT M8 P/N 5001787
torque: 11 lbf-ft

MI16-17E / Page 10 / 26
25. Fit the ground cables onto their respective
alternator ground studs. For each alternator,
place one flat washer F against the ground
cable lug and screw nut G.
FIGURE 20
F: FLAT WASHER P/N 502573
G: NUT M6 P/N 5001182
torque: 6 lbf-ft
H : GROUND CABLES
26. On the upper alternator, plug alternator
harness onto alternator connector and secure
using nylon cable ties P/N 504637 positioned
as shown by red arrows on FIGURE 21.
NOTE: one nylon tie is used to block the
connector locking mechanism in order to
prevent
unwanted
unlocking
and
disconnection.
FIGURE 21
27. On the lower alternator, plug alternator
harness onto alternator connector and secure
using nylon cable ties P/N 504637 positioned
as shown by red arrows on FIGURE 22.
NOTE: one nylon tie is used to block the
connector locking mechanism in order to
prevent unwanted unlocking and disconnection
FIGURE 22

MI16-17E / Page 11 / 26
28.
Apply anti-corrosion compound or Color Guard Rubber Coating (Prevost p/n: 684013) on
alternator terminals, cable lugs and nuts.
29. Mount the alternator belt tensioner bracket
assembly loosely using previously removed
bolts I & J (FIGURE 23).
FIGURE 23
I: SCREW CAP HEXF M8-1.25X50 G10.9 p/n 500796 qty.1
J: SCREW CAP HEXF M10-1.25X55 G10.9 p/n 5001801 qty.2
30. Install the reinforcement bracket. Use two
previously removed cap screws E and flat
washers. DO NOT apply final torque at this
moment.
Note: Use blue Loctite 243 on threads.
Note: Once thread locker is applied, do not
wait too long before applying final torque.
Final tightening will be done in the next
following steps.
Cap screw E according to clutch type
Lang clutch screw E p/n 5001616
Torque 40 lbf-ft (54 N-m)
FIGURE 24
LINNIG clutch screw E p/n 502949
Torque 32 lbf-ft (43 N-m)

MI16-17E / Page 12 / 26
31. Continue with the installation of the
reinforcement bracket as shown using
previously removed hardware (bolt C finger
tightened and flat washer). DO NOT apply
final torque at this moment.
Note: Use Blue Loctite 243 on threads.
Note: Once thread locker is applied, do not
wait too long before applying final torque.
FIGURE 25
32. If bolts C & E (see two previous steps) are
difficult to align in the hole, the compressor
may be moved. Loosen the compressor
mounting bolts (4x) at the base (see FIGURE
26
STREET SIDE
COMPRESSOR MOUNTING
BOLTS
CURBSIDE COMPRESSOR
MOUNTING BOLTS
FIGURE 26
33. Snug bolts C & E (FIGURE 24 & FIGURE 25).
34. Snug compressor mounting bolts at the base.
35. Snug bolts I & J indicated with arrows on
FIGURE 27.
Note: Use blue Loctite 243 on threads.
36. Tighten the compressor mounting bolts to 74
lbf-ft. (100 N-m).
FIGURE 27
37. Tighten the three bolts shown on FIGURE 28 to
prescribed torque.
FIGURE 28

MI16-17E / Page 13 / 26
38. Tighten bolts C and bolt E (refer to
29).
FIGURE
Lang clutch: E= 40 lbf-ft (54 N-m)
Linnig clutch: E= 32 lbf-ft (43 N-m)
FIGURE 29
C= 74 lbf-ft (100 N-m)
39. Reinstall the alternator belt. To do so, rotate
the automatic tensioner using a ½ square drive
breaker bar and install the belt as shown on
FIGURE 30.
FIGURE 30
40. Reinstall tensioner, bolt and washer B and
bolt and nut A. Do not tighten these bolts at
this moment as the belt tension adjustment
will be done later in this procedure.
FIGURE 31

MI16-17E / Page 14 / 26
41. Install the electromagnetic clutch coil (for
Linnig clutch, refer to PART 3). Position cable
lead near the 2 o’clock position.
FIGURE 32
42. Slip the coil on the retainer on the compressor
flange. Fasten the coil with 4 cap screws
#5001775 to the compressor.
Use blue Loctite 243.
Caution: parts should be clean and free from
debris. Pay attention to the precise seat of
coil. The coil should sit flush with the face of
the compressor.
FIGURE 33
F: Coil mounting cap screws
torque: 22 lbf-ft

MI16-17E / Page 15 / 26
43. Mount the rotor on the shaft end.
The flange and the shaft end of the
compressor must be clean and free from dirt.
The flange and the shaft end of the
compressor must be free from dirt. Apply
high temperature approved assembly
grease on the shaft end for easy
dismounting
of
the
clutch.
Lang
recommends the use of Molykote G-rapidplus or Molykote P 40.
44. Carefully mount the rotor on the shaft end by
hand.
FIGURE 34
Never use a hammer for pressing the rotor on.
Align the key on the compressor shaft with the
keyway on the pulley bore. To avoid
damaging the bore of the rotor, feel the
engagement of the key in the keyway and slip
the rotor on the shaft end of the compressor
till reaching the stop (FIGURE 32).
The Woodruff key on the shaft end and the
groove in the location hole of the rotor must
be flush.
45. Fasten the rotor to the shaft end using the
M12 screw and by holding-up with a wrench
on the rotor.
46. Turn rotor by hand and pay attention to the
free run and the generation of noises. In case
of grinding or similar noises, dismount the
clutch and check installation.
USE BLUE LOCTITE 243 ON THREADS
FIGURE 35
G: ROTOR MOUNTING SCREW
torque 60 LBF-FT (81 N-M)

MI16-17E / Page 16 / 26
47. Reinstall A/C compressor drive belts.
A belt strand tension gauge is needed. Belt
tension should be within the following range:

90-100 lbs new belts (mean of 2 belt
values)

75-85 lbs used belts (mean of 2 belt
values)
Single 5VX810 belt (FIGURE 37)

150-160 lbs new belt

120-130 lbs used belt
FIGURE 36
48. Apply blue Loctite 243 on bolt B threads and
then hand-tighten bolt B. Adjust belt tension
using bolt A. Use the jam nut at the base of
bolt A to keep proper tension adjustment.
Note: Once thread locker is applied, do not
wait too long before applying final torque.
When proper tension is achieved, tighten bolt
B to 43 lbf-ft. (58 N-m).
FIGURE 37
FUNCTIONAL TEST
1. 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.

MI16-17E / Page 17 / 26
PART 2 – PULLEY REMOVAL / INSTALLATION
SPECIAL TOOLS REQUIRED TO TIGHTEN THE ALTERNATOR PULLEY MOUNTING NUT
METRIC 10mm 12-POINTS SPLINE DRIVE LONG (CARLYLE SLTS3810M AVAILABLE FROM NAPA )
OFFSET 7/8 WRENCH (CYLINDER HEAD WRENCH), SNAP-ON PART
NUMBER M4201
7/8 SOCKET (PART NUMBER WA2828A)
OFFSET 7/8 WRENCH FITTED WITH 7/8 SOCKET AND 10mm 12-POINTS
SPLINE DRIVE

MI16-17E / Page 18 / 26
USING THE CYLINDER HEAD WRENCH
RATCHET AND A FLEX SOCKET WRENCH
WITH
A
PULLEY REMOVAL / INSTALLATION
FIGURE 38
1. Unscrew the alternator pulley mounting nut
(FIGURE 39).
2. Remove the alternator pulley (2 pulleys).
FIGURE 39

MI16-17E / Page 19 / 26
SPECIAL CASE ON 150A ALTERNATOR
One (1) flat washer #500449 is required between the pulley and the flange nut
3. Mount pulley onto alternators. Use Loctite 243
blue on threads. Tighten pulley mounting nut to
75 lbf-ft using special tools and a M10 12points spline drive mounted on a torque
wrench.
FIGURE 40

MI16-17E / Page 20 / 26
PART 3 – ASSEMBLY INSTRUCTIONS FOR ELECTROMAGNETIC CLUTCH – LINNIG LA16
Assembly instruction:
1.
Attach coil according to instruction manual of the compressor manufacturer. Connect cable in a
way that avoids contact with hot components (only if coil contents a cable). t max = 105°C
2.
Remove circlip and holding-down bolt from clutch- assembly. Slide clutch-assembly onto
compressor shaft. Look through the center-hole for a correct position of the compressor shaft key
in the rotor-keyway. Rotor should turn freely without touching the coil. Consider the control mark!
Insert and tighten holding-down bolt M12 (tightening torque Ma = 85 Nm, Ma = 63 lbs-ft). Hold
down the rotor with an open-ended spanner or ring spanner WAF41. Insert circlip.
3.
Slide pulley over the stud screws (1) and bolt on with nuts M8 DIN 934-8 (2) (only for LA16.3; for
other LA16 is pulley integrated part of the clutch).
Connect cable respectively connector. The connection is independent of polarity. Allowed
operating voltage 21–32 VDC.
4.
Disassembly instruction:
For disassembly grease circlip (do not remove circlip) and turn the holding-down bolt left to
loosen. Hold down the rotor with an open-ended spanner or ring spanner WAF41. In this way the
clutch will be disconnected from the cone-shaft.
LINNIG ELECTROMAGNETIC CLUTCH INSTALLATION/REMOVAL

MI16-17E / Page 21 / 26
PART 4 –HOT SIDE SINGLE BOSCH ALTERNATOR REMOVAL AND INSTALLATION
DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position, the battery master switch (master cut-out) to the OFF position and
trip the main circuit breakers equipped with a trip button.
RISK OF ELECTRICAL SHOCK

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 prior disconnecting the alternator cables.
HOT SIDE SINGLE ALTERNATOR REMOVAL
1. Rotate the automatic belt tensioner A
clockwise using a ½ square drive breaker
bar and then remove the alternator drive
belt B.
FIGURE 41

MI16-17E / Page 22 / 26
2. Cut the nylon ties securing the cables to
the alternator and then disconnect the
alternator cables A, B & C. Properly clean
cable lugs as applicable using a brass wire
cup brush, a Scotch-Brite pad or an emery
cloth.
Keep hardware for reuse.
FIGURE 42
A: (+) POWER CABLE
B: GROUND CABLE
C: ALTERNATOR HARNESS
3. Remove the alternator. To do so, unscrew
the two (2) mounting bolts identified on
FIGURE 43.
Keep hardware for reuse.
FIGURE 43
HOT SIDE ALTERNATOR INSTALLATION

MI16-17E / Page 23 / 26
4. Apply anti-seize compound (Prevost p/n:
680335) inside the alternator mounting
ears and inside the sleeves found on the
support attached to the engine (see FIGURE
44 & FIGURE 45).
FIGURE 44
FIGURE 45
5. Reinstall the alternator using previously
removed bolts A & B (FIGURE 46).
Use Loctite 243 Blue on threads
6. To ease installation, loosen bolt C if
necessary (FIGURE 46).
FIGURE 46
A:
SCREW HEXF P/N 5001308 M10-1.25X40 G10.9,
NUT P/N 5001727
torque: 48lbf-ft
B:
SCREW HEXF P/N 502960 M12-1.75X160 G10.9,
NUT P/N 5001728
torque: 82 lbf-ft
C:
SCREW HEXF P/N 5001799 M10-1.5X70 G10.9,
NUT P/N 5001727
torque: 48 lbf-ft

MI16-17E / Page 24 / 26
7. Connect the (+) power cable A, the ground
cable B and alternator harness C to the
alternator (FIGURE 47).
8. Fit the (+) power cable terminal onto
adaptor stud at B1+ stud terminal, place
one flat washer E against the (+) power
cable lug and screw nut D (FIGURE 48).
STUD ADAPTER p/n 060297 torque: 11 lbf-ft
FIGURE 47
A: (+) POWER CABLE
B: GROUND CABLE
C: ALTERNATOR HARNESS
9. Connect the ground cable onto the
alternator ground stud terminal as shown
on FIGURE 48. Place one flat washer F
against the ground cable lug terminal and
screw nut G.
FIGURE 48
D: NUT M8 P/N 5001787
torque: 11 lbf-ft
E: FLAT WASHER P/N 5001341
F: FLAT WASHER P/N 502573
G: NUT M6 P/N 5001182
torque: 6 lbf-ft

MI16-17E / Page 25 / 26
10. Secure the alternator harness using nylon
cable ties P/N 504637 positioned as shown
by red arrows on FIGURE 49.
NOTE: one nylon tie is used to block the connector
locking mechanism in order to prevent
unwanted unlocking.
FIGURE 49
11. Apply anti-corrosion compound or Color Guard Rubber Coating (Prevost p/n: 684013) on
alternator studs, cable lugs and nuts.
FUNCTIONAL TEST
12. 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.

MI16-17E / Page 26 / 26
PARTS / WASTE DISPOSAL
Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)
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