Remy 55SI™ HD ALTERNATOR REPLACEMENT - Manual

Instruction Sheet
10528830
04OC13 REV2
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
40SI ™ & 55SI™ HD ALTERNATOR REPLACEMENT PARTS INSTRUCTIONS
These instructions explain how to replace the serviceable components from these alternators.
NOTE: It is beneficial and possibly necessary to obtain the miscellaneous hardware package, for reassembly of the alternator.
It is preferable to use new, undamaged parts.
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
®
ALTERNATORS. 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 burn skin or damage tools and surrounding parts.
FOLLOW ENGINE OR VEHICLE MANUFACTURER’S INSTRUCTIONS CAREFULLY WHEN REMOVING AND REINSTALLING
THE ALTERNATOR.
REMOVAL AND INSTALLATION INSTRUCTIONS FOR FAN - ROTOR - RE BEARING - DE FRAME (WITH BEARING)
REFERENCE: There is an exploded parts view of the 40SI & 55SI alternators for easy reference on page 2. More detailed exploded
views can be found on the www.delcoremy.com web site under product support and service parts.
1. Disconnect the negative (-) cable at the batteries.
2. Remove vehicle leads connected to the alternator, noting their positions for reinstallation of the alternator.
3. Remove the pulley nut, pulley and fan. If replacing the fan, dispose of it and go installation step 5.
4. Remove the drive end (DE) frame and rotor assembly, by removing the four (4) thru-bolts (mark the frames for reassembly) that hold
the end frames together.
5. Separate the rotor, collar and spacer, using a press, from DE frame. If replacing rotor, dispose of it and go to installation step 3.
NOTICE! ! It is recommended that the DE & RE bearings be replaced when replacing the rotor.
6. If replacing the rectifier end (RE) bearing, remove RE cover and remove the bearing, using a press. Go to installation step 2 .
7. If replacing the DE Frame (with bearing), dispose of it and go to installation step 3.
8. If replacing the DE bearing, remove the four (4) screw assemblies and bearing retainer plate. Using a press, remove and dispose
of the bearing and go to installation step 1.
INSTALLATION INSTRUCTIONS
1. Install the new DE bearing, using a press, into the DE frame until seated. Install the new retainer plate and torque the four (4) new
screw assemblies to 8.4-9.6 Nm (40-50 lb in).
2. If removed, install the RE bearing into the frame with a press. See graphic on page 2, for correct dimensional location of bearing in
the frame.
3. Install the old or new collar and spacer onto the old or new rotor. Using a press, push the rotor assembly into the DE frame until
seated.
4. Reassemble the DE and RE frames, being sure to line up the non threaded lugs or marks on the frames. Install the four (4) thru
bolts and torque to 50% of final value. Use a staggered sequence to finish and torque thru-bolts to 11.3-13.6 Nm (8-10 lb ft).
5. Install old or new fan, pulley and nut. Torque the pulley nut to 95-108 Nm (70-80 lb ft).
6. Reinstall alternator according to engine or vehicle manufacturer’s instructions.
7. Reattach the battery (+) terminal lead, as removed, and torque nut to 9.0-13.5 Nm (80-120 lb in).
8. Reconnect the negative (-) cable at the battery.
REMOVAL AND INSTALLATION INSTRUCTIONS FOR RE COVER - RE FRAME ASSEMBLY (WITH RECTIFIER, STATOR &
REGULATOR) - STATOR - RE FRAME ASSEMBLY (WITH RECTIFIER & REGULATOR) - VOLTAGE REGULATOR
REFERENCE: There is an exploded parts view of the 40SI & 50SI alternators for easy reference on page 2. More detailed exploded views
can be found on the www.delcoremy.com web site under product support and service parts.
1. Disconnect the negative (-) cable at the batteries.
2. Remove vehicle leads connected to the alternator, noting their positions for reinstallation of the alternator.
3. Remove the four (4) RE cover screws. If replacing the RE cover, dispose of it and go to installation step 7.
NOTICE! ! Avoid excessive heat when melting or soldering connections. Excessive heat may damage the terminals or leads, causing
premature alternator failures.
4. If replacing the regulator, apply just enough heat to the rectifier connection to melt solder and carefully pry the crimp
open. To remove the regulator, cut the insulator just above the insulated screw hole and save the part.
5. Remove and dispose of regulator, saving the insulator and screws for reassembly. Go to installation step 4.
6. If replacing the RE frame assembly (rectifier, stator & regulator), mark the frames for reassembly.
7. Remove the four (4) thru-bolts, saving bolts for reassembly, and separate the end frames. Dispose of RE frame
assembly and go to installation step 2
.