Remy 22SI "I Terminal Retrofit Kit 10511625" - Manual

Instruction Sheet
10511625
19JL13 C/P30502 REV3
NOTICE - Only licensed Remy International, Inc. product and component parts should be used, and the use of other parts or modifications not approved
by Remy International, Inc. will void all applicable warranties. The failure to carefully follow these Installation Instructions, set forth above, will void all
applicable warranties. DELCO REMY is a registered trademark of General Motors Corporation, licensed to Remy International, Inc. Pendleton, IN 46064.
©
2012 Remy International, Inc. All rights reserved 1
“I” Terminal
I
R
GRD
21SI & 22SI "I" TERMINAL RETROFIT KIT
WARNING!!!! ALWAYS USE PROPER EYE PROTECTION WHEN PERFORMING ANY MECHANICAL REPAIRS TO A VEHICLE –
INCLUDING, BUT NOT LIMITED TO, ANY INSTALLATION AND OR REPAIRS TO THE DELCO REMY ALTERNATOR. FAILURE TO
USE PROPER EYE PROTECTION CAN LEAD TO SERIOUS AND PERMANENT EYE DAMAGE.
Only perform the mechanical functions that you are properly qualified to perform. Mechanical repairs that are beyond your te chnical
capabilities should be handled by a professional installation specialist.
DANGER!!! To avoid injury or damage, always disconnect the negative cable at the battery before removing or replacing the alternator.
The alternator output terminal is always live (“hot”). If the battery is not disconnected, a tool accidentally touching this terminal and
ground can quickly get hot enough to cause skin burn or damage to the tool and surrounding parts.
The parts in this kit are supplied to add an "I" terminal to a 21SI Alternator that does not have such a terminal. The kit includes a diode that
must be installed in the external wire that is attached to the terminal. The diode must be installed as described in the instructions to allow
current to flow into the terminal from a switched B + source during start-up, but will block current flow in the opposite direction under other conditions.
1. Mark side of alternator for alignment when reassembling
alternator. Remove four thru-bolts and separate drive end frame (with
rotor) from slip ring end housing (with stator).
2. Remove three rectifier bridge nuts,
then separate stator from slip ring end
housing.
3. Locate brushes inside slip ring end housing, push into retracted position and insert pin
through holes in housing and brush holder to hold. Be
sure pin will be removable from o u t s i d e of
housing during reassembly. Cover open end of bearing with tape to prevent dirt entry.
4. Remove regulator stud connector from inside slip ring
end housing by removing regulator stud nut and inside
output (BAT) terminal nut. Note that output (BAT) terminal
may fall out when nut is removed. Also remove insulated
regulator attaching screw.
5. Locate “I” Terminal hole in slip ring end housing. Select new square or round “I” terminal insulator to match
hole shape. (Note: If round, use file to round corners of smaller square shank on new terminal stud to fit
easily into round insulator.) Insert “I” terminal into new insulator and then install assembly through hole from
outside, seating insulator in housing. Place new insulating washer over terminal threads on inside of housing.
Place new “I” terminal connector and nut loosely onto threads.
6.
Position other end of “I” terminal connector over mounting hole on regulator, then reinstall
insulated regulator mounting screw through d
iode trio connector, “I” terminal connector, and
regulator. Tighten screw to 2.0 Nm (20 lb in). Tighten inside nut on “I” terminal to 2.5 Nm (22 lb
in). Note: If hole in housing is round, hold large square shank on terminal as anti-turn while
tightening.
Alignment Marks
Brush Pin Hole
Cover Open Bearing