Remy REPLACING DELCO REMY 24SI ALTERNATATORS - Manual

Instruction Sheet
10513391
19JL13 C/P30502 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
24SI ALTERNATOR INSTRUCTIONS FOR REPLACING
DELCO REMY 21SI, 22SI, 23SI AND 24SI ALTERNATATORS
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. A professional installation specialist should handle
mechanical repairs that are beyond your technical capabilities.
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 to the tools and surrounding parts.
FOLLOW ENGINE OR VEHICLE MANUFACTURER’S INSTRUCTIONS FOR REMOVING THE OLD ALTERNATOR FROM THE
ENGINE AND INSTALLING THE NEW ALTERNATOR.
PULLEY INSTRUCTIONS: Use pulley from old alternator if this alternator does not have a pulley or pulley supplied is different from the
one on alternator being replaced. NOTICE! When changing the pulley, keep the alternator in the horizontal position and do not
apply any pressure to end of the shaft. Internal damage will occur if the shaft is
pushed back and turned. If there were spacers, when the fan (21SI & 22SI) and pulley were
removed, make sure all spacers are replaced when installing the pulley on the 24SI alternator. Hold the
shaft by placing
an 8.01 mm (5/16”) hex wrench in the hexagonal hole in the shaft while removing or
installing the pulley. Tighten the pulley nut to 95-108 Nm (70-80 lb ft).
FAN: Do not install external fan from alternator being replaced. The 24SI alternators have dual
internal cooling fans and do not require an external fan.
NOTICE! This alternator is designed for use in a Clock-Wise (CW) direction only if you are looking at
pulley side (front) of alternator. Do not install on a Counter-Clock-Wise (CCW) application.
BELT TENSIONING INSTRUCTIONS: Improper belt tension can cause premature alternator failure.
If the belt must be tightened manually, place a wood block between the alternator and pry bar (See
illustration). Pry as close to the center of the unit as possible. Use a torque wrench to tighten mounting
bolts to specified torque. Follow vehicle or engine manufacturer’s specifications carefully for belt tension
and mounting bolts torque. DO NOT OVER TIGHTEN BELT!
INSTALLATION INSTRUCTIONS (See illustrations, page 2):
 Disconnect the negative (-) cable at the batteries.
 Identify and tag all leads when removing the old Alternator and install them on the same terminals of the 24SI Alternator.
 Some 21SI and 22SI applications will require enlarging the ring terminals. Most will also require wiring modifications and use of the
adaptor illustrated below.
 Cut lead, strip insulation 1/4- 3/8”, insert wire into appropriate colored terminal, crimp terminal and using a Heat Gun, apply
heat to Heat Shrink tube until it forms and seals around lead.
 Install the output (BAT) lead and torque nut to 6.2-7.9 Nm (55-70 lb in).
 Install the ground (GRD) lead and torque screw to 9.0-13.6 Nm (80-13.6 lb in).
 Plug and seat the regulator or adaptor connector into the alternator regulator connection.
 Ensure all leads are hooked back up or contained where they cannot ground.
 This 24SI may have more terminals than the alternator it is replacing had or used. It will function properly by only hooking up the
leads that were used on the alternator being replaced.
REPLACING A 21SI OR 22SI ALTERNATOR THAT HAS A 2-TERMINAL VOLTAGE REGULATOR
 REPLACING THESE MODELS REQUIRES USING THIS WEATHER PACK CONVERSION ADAPTOR KIT
Notice! Do not install the Remote Sense ™ line (# 2 Regular terminal on some 21SI & 22SI models) to the Relay (red lead).
PHASE (RELAY) “P”: RED LEAD
IINDICATOR LAMP “L”: BLUE LEAD
REMOTE SENSE “S”: YELLOW LEAD
VOLTAGE REGULATOR
CONNECTOR