Remy 24SI™ HD - Manual

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24SI ™ HD REPLACEMENT PARTS INSTRUCTIONS
These instructions explain how to replace the serviceable components from these assemblies.
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.
THE RECTIFIER POSITIVE HEAT SINK INSULATOR SHOULD ALWAYS BE REPLACED
WARNING!!!! ALWAYS USE PROPER EYE PROTECTION WHEN PERFORMING ANY MECHANICAL REPAIRS TO A
AVEHICLE – 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
DAM AG E
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Only perform the mechanical functions that you are properly qualified to perform. Mechanical repairs that are beyond your
technical 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 DE FRAME - STATOR - DE BEARING - SRE ROTOR BEARING
- ROTOR WITH BEARING ASSEMBLY
REFERENCE: There is an exploded parts view of the 24SI alternator for easy reference on page 3. 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, drive end slinger and external drive end spacer.
NOTICE! ! Excessive movement may weaken or break a lead or leads between the stator and rectifier assemblies. The
rotor should not be replaced without removing the brush holder to ensure the bearing retainer is in place.
4. Remove the four (4) thru-bolts that hold the DE and SRE frames together. Remove the DE frame assembly, being
careful not to disturb the stator or pull the rotor from the SRE housing. Go to step 8 to replace stator.
5. If replacing DE frame assembly, dispose of it. Go to installation step 6.
6. If replacing DE bearing, remove the three (3) screw assemblies and bearing retainer plate.
7. Remove and dispose of the old DE bearing. Go to installation step
4 .
NOTICE! ! Avoid excessive heat when melting or soldering connections. Excessive heat may damage the terminals or
leads, causing premature alternator failures.
8. If replacing the stator, remove the SRE cover. Apply just enough heat to stator lead wire crimp connections to melt
the solder and carefully pry the wire crimps open, three (3) places. If not replacing stator, continue to step 10.
9. Remove and replace the stator with the new one. Crimp and solder the three (3) stator wire connections to the
rectifier assembly. Go to installation step 6 .
10. If replacing the rotor with bearing assembly, remove and dispose of it, being careful not to disturb the stator
assembly. Seat the bearing on the new rotor assembly per below instructions.
The bearing must be seated against the fan on the new rotor assembly prior to installation. Using a press, being
careful not to use excessive force, push equally on both bearing races until seated against fan
11. Reinstall slinger onto rotor assembly, using a press. If damaged, install a new slinger. Go to installation step 1
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NOTICE! ! Removing SRE bearing without damaging the rotor assembly is very difficult without using specialized tooling
developed for that purpose.
12. If replacing SRE rotor bearing, remove the slinger and bearing. Dispose of the bearing.
13. Install new bearing and seat onto the rotor per instructions in above step 10. Reinstall the slinger per instructions in
above step 11. Go to installation step 1.
14. Remove the slip ring end (SRE) cover.
15. Remove the voltage regulator and brush holder assembly, because the bearing retainer may need to be reseated or
replaced. If it becomes necessary to remove the rectifier assembly, go to removal instructions page 2, step 9. Be
sure to note the location of the insulated screw for reassembly.
INSTALLATION INSTRUCTIONS
1. Install rotor with bearing assembly, being careful not to disturb the stator assembly.
2. Reinstall brush holder and voltage regulator. NOTE: If rectifier assembly was removed, be sure to reinstall the
insulated screw in the same hole as removed to avoid electrical damage.
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
Instruction Sheet
10528572
13SE13 Rev. 1