Remy REPLACING 25SI REGULATOR - Manual (Page 2)

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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.
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2012 Remy International, Inc. All rights reserved 2
7. See Fig. 2. Locate three yellow leads coming out of diode trio on
same side as red lead. Connect each lead to a different rectifier
bridge terminal, using three nuts removed and left loosened
earlier. Be sure all leads to each of these terminals are
properly reconnected. Tighten nuts to 3.0 Nm (26 lb in).
8. Install remaining yellow lead coming out of diode trio (on same side as
blue lead) to inside of "R" terminal with existing attaching nut
(Fig 2). It may be necessary to hold hex shoulder on
outside of terminal as anti-turn while tightening nut. Tighten
nut to 2.3 Nm (20 lb in). Be sure terminal lead does not touch
housing after tightening.
9. See Fig. 3. Coat back (metal side) of new regulator with
silicone dielectric grease (Loctite® 5840, in package). Place
regulator onto base plate, aligning 3 mounting holes (B, C, D)
in each. Position blue lead from diode trio and one field coil
lead
over mounting
hole B (see illustration), then insert 1 inch long
insulated screw through regulator and base plate. Install nut/lockwasher assembly. Be sure the 3
regulator and base plate mounting holes are still aligned. Hold screw at hex cap and tighten nut to 3.0
Nm (26 lb in).
10. See Fig. 4. Coat areas on back of base plate (side away from regulator) that will touch rectifier
housing with silicone dielectric grease (Loctite
®
5840, in package). Coat ends of spacer with
same grease, then place spacer over newly drilled mounting hole C. Place regulator/plate
assembly into housing and align to mounting holes. Blade terminals on regulator MUST
NOT touch alternator housing – trim ends of terminals if necessary to avoid contact.
Install 1/2 inch long screw (provided in package) to hole A in base plate and old mounting hole
in housing (finger tighten).
11. See Fig. 4. Insert 2 inch long insulated screw (in package) through re maining
field coil lead then coat threads with high temperature adhesive/sealant (Loctite® 620, in
package). Without getting sealant on surface of regulator contact, insert screw through regulator,
base plate, and spacer into newly drilled mounting hole C (finger tighten).
12. See Fig. 4. Install 1 inch long screw (provided in package) through regulator
and base plate, and into newly drilled mounting hole D.
13. Tighten screw in existing mounting h o l e A t o 3 . 0 N m (26 lb in).
Tighten screws in newly drilled mounting holes C and D to 3.4 Nm (30 lb in).
The screw in hole D is a grounding screw - be sure regulator is held
securely. Note: W hen reinstalling screws in previously used
mounting holes C and D, tighten to 3.0 Nm (26 lb in).
14. See Fig. 2. Install yellow sense lead loosely to threaded stud on regulator
with nut/lockwasher assembly, routing lead through grommet to heat sink
attaching screw. Remove heat sink screw, plain washer, and insulator.
Place sense lead connector over hole and reinstall insulator, washer, and
screw. Sense lead must be under insulator. Tighten heat sink screw to 3.0
Nm (26 lb in).
15. Place rectifier cover back onto rectifier end assembly and reinstall attaching
screws. Tighten screws to 5.3 Nm (47 lb in).
16. Install end plate to rectifier end assembly and reinstall attaching screws.
Tighten screws to 3.0 Nm (26 lb in).
17. Check inside of rectifier and assembly for new metal shavings that may have
been created by installation of self-tapping screws into newly drilled mounting
holes. Remove all traces of metal shavings.
18. Remove protective tape from open end of bearing in rectifier end
assembly. Assemble drive-end assembly (with rotor) to rectifier end
assembly. Install thru-bolts and tighten to 6.0 Nm (55 lb in).