Remy 55SI™ HD ALTERNATOR REPLACEMENT - Manual (Page 2)

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 2
Technical support: USA 800 854 0076, Mexico 01 800 000 7378, Brazil 0800 703 3526, South America 55 11 2106 6510 or visit
delcoremy.com
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8. If replacing the stator or RE frame assembly (rectifier & regulator), apply just enough heat to the three (3) wire crimps to rectifier
connections to melt solder. Pry the crimps open carefully and separate the assemblies.
9. If replacing stator, dispose of it and go to installation step 1.
10. If replacing RE frame (with rectifier & regulator), dispose of it and go to installation step 1.
INSTALLATION INSTRUCTIONS
1. To replace either the stator or RE frame (with rectifier & regulator), slide the frame over the three (3) stator wires. Crimp and solder
the wires to the rectifier terminals by applying just enough heat melt the solder.
2. Reassemble end frames, using either the repaired unit from step 1 or a new RE frame assembly (with rectifier, stator & regulator). Be
sure to match them up the non threaded lugs or marks on the frames.
3. 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).
4. Place the voltage regulator onto the RE frame, install insulator and four (4) mounting screw assemblies. Torque all screws to 2.5-
3.4 Nm (22-30 lb in).
5. Crimp and solder the regulator to rectifier connection by applying just enough heat to melt the solder.
6. Reinstall the drive end frame assembly, being careful to line up the non-threaded mounting lugs or marks.
7. Reinstall rectifier end cover and torque the four (4) mounting screw assemblies to 4.5-5.7 Nm (39-50 lb in).
8. Reinstall alternator according to engine or vehicle manufacturer’s instructions.
9. Reattach the battery (+) terminal lead, as removed, and torque nut to 9.0-13.5 Nm (80-120 lb in).
10. Reconnect the negative (-) cable at the battery.
EXPLODED PARTS VIEWS OF 40SI & 55SI ALTERNATORS AND OTHER PRODUCTS ARE AVAILABLE ON THE
www.delcoremy,com WEBSITE UNDER PRODUCTS AND SERVICE PARTS.
40SI ™ & 55SI™ SERVICE PARTS
40SI & 55SI SERVICE PARTS PACKAGES
1. FAN
2. DRIVE END FRAME WITH BEARING
3. DRIVE END BEARING PACKAGE
4. ROTOR PACKAGE
5. RECTIFIER END COVER PACKAGE
6. RECTIFIER END FRAME ASSEMBLY
(Rectifier, Regulator, Stator)
7. STATOR
8. VOLTAGE REGULATOR
9. RETIFIER END FRAME ASSEMBLY
(Rectifier, Regulator)
10. HARDWARE PACKAGE
11. RECTIFIER BEARING PACKAGE
HARDWARE PACKAGE MAY BE NECESSARY
40SI 55SI