Remy 24SI™ HD User Manual
Page 2
3. Crimp and solder the voltage regulator connection and rectifier connections if necessary.
4. Install new drive end bearing assembly into drive end frame. Push bearing into frame bore until it is seated, by
applying force against the outer race only, using a press. Do not use excessive force.
5. Reinstall or replace bearing retainer plate. Torque the three (3) screws & lock washer assemblies to 5.0-9.0 Nm
(44-80 lb in).
6. Reinstall the drive end frame assembly, being careful to line up the non-threaded mounting lugs.
7. Reinstall the four (4) thru-bolts. Using a crossing pattern, torque the four (4) thru-bolts to 7.8-9.2 Nm (90-120 lb in).
8. Reinstall slip ring end cover and torque the mounting screw assemblies to 2.2-2.8 Nm (19-25 lb in).
9. Reinstall external DE end spacer, DE slinger, pulley and pulley nut. Tighten pulley nut to 95-108 Nm (70-80 lb ft).
10. Reinstall alternator according to engine or veh
icle manufacturer’s instructions.
11. Reattach the battery (+) terminal lead, as removed, and torque nut to 9.0-13.0 Nm (80-120 lb in).
12. Reconnect the negative (-) cable at the battery.
REMOVAL AND INSTALLATION INSTRUCTION FOR SRE COVER - VOLTAGE REGULATOR - BRUSH ASSEMBLY -
RECTIFIER ASSEMBLY- SRE FRAME
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 thweb site under products 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 SRE cover. If replacing, dispose of it and go to installation step 9.
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, separate regulator from the rectifier assembly by applying just enough heat to the
connection to melt solder and carefully pry the crimp open
5. Remove the regulator mounting screws and bushings, carefully noting parts orientation for reassembly. Dispose of
regulator and go to installation step 7.
6. If replacing brush assembly, remove the four (4) thru-bolts holding the DE and SRE frames together and remove the
regulator as noted in steps 4 & 5 above.
7. Remove and dispose of the brush assembly and go to installation step 4.
NOTE: If it should require removing the
rectifier continue to step 8.
8. If replacing rectifier assembly, separate rectifier assembly from stator by applying just enough heat to melt solder at
the three (3) wire crimp stator connections and carefully prying wire crimps open. If not replacing rectifier assembly,
remove as a unit with the regulator attached.
9. Remove rectifier assembly fasteners.
WARNING
! Note location of the insulated screw assembly on the end of the
positive heat sink next to the battery terminal for reassembly. Failure to use an insulated screw assembly here will
cause a ground and damage the alternator and potentially surrounding parts.
10. Remove heat sink insulator, being extremely careful not to damage surface of SRE casting.
11. Dispose of the old rectifier assembly. Go to installation step 5.
12. Remove and dispose of SRE frame by removing the four (4) thru-bolts that hold DE & SRE frames together. Go to
installation step 1.
INSTALLATION INSTRUCTIONS
1. Place new SRE frame over the stator leads, being careful to line up the non-threaded mounting lugs.
2. Using a crossing pattern, install and torque the four (4) thru-bolts to 7.8-9.2 Nm (90-120 lb in),
3. Reinstall and seat the bearing retainer in SRE frame bore. If damaged, install a new retainer.
4.
Reinstall brush holder assembly. Prior to assembly, push the brushes back, and insert a 17 mm (.7”) pin to
hold them back to allow clearance for the slip ring to enter.
5. Place new heat sink insulator onto positive heat sink of the new rectifier assembly, if necessary. Cover
negative diodes with a heat sink compound compatible with semiconductor materials. Use a compound that
can with stand a temperature range of -40C to 180C (- 104F to 356F).
6. Reinstall five (5) mounting screws into the rectifier assembly, ensuring the one (1) insulated screw is installed
in the hole on the rounded end of the positive heat sink, as removed. Torque all screws to 2.2-2.8 N-m (19-
25 lb in).
7. Install voltage regulator by replacing two (2) bushings and three (3) mounting screws into the voltage regulator,
ensuring the one insulated screw is used in terminal that connects to the brush holder. Torque all
screws to 2.2-2.8 N-m (19-25 lb in).
8. Crimp and solder rectifier assembly terminals to three (3) stator wires and to voltage regulator strap.
9. Install SRE cover and torque the mounting screw assemblies to 2.2-2.8 N-m (19-25 lb in).
10.
Reinstall alternator according to engine or vehicle manufacturer’s instructions.
11. Reattach the battery (+) terminal lead to alternator battery terminal and torque nut to 9.0-13.0 N-m (80-120 lb in).
12. Reconnect the negative (-) cable at the battery.
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
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