Remy REPLACING DELCO REMY BOSCH K1 ALTERNATORS - Manual

Instruction Sheet
10510589
12JL13 C/P30502 REV3
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
11SI ALTERNATOR INSTALLATION INSTRUCTIONS
FOR REPLACING DELCO REMY 10SI, 11SI, 12SI OR BOSCH K1 ALTERNATORS
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 OR BOSCH 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 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 termi
nal is always live (“hot”). If the battery is not disconnected, a tool accidentally touching this terminal and
ground can quickly get hot enough to cause skin burn or damage to the tool and surrounding parts.
Follow engine or vehicle manufacturer's instructions for removing the old alternator from the engine and installing the new alternator.
The alternator supplied in this package may have more terminals than the one being replaced. This alternator will operate
properly by connecting only the phase and lamp terminals from the old alternator
(These terminals are identified with a “P” and “L”
on the voltage regulator connector of the alternator).
PULLEY INSTRUCTIONS: Use the pulley from old alternator if this alternator does not have a pulley or pulley supplied is different from
the one on alternator being replaced. Hold the shaft by placing a 5/16” hex wrench in the hexagonal hole in the end of the shaft while
removing or installing the pulley. Tighten the pulley nut to 80-110 Nm (59-81 lb in). If there are any spacers, when removing the fan and
pulley, make sure all spacers are replaced when installing the pulley on the 11SI alternator. Dispose of fan. This procedure applies to
all alternators being replaced.
FAN: Do not attempt to install fan from the old alternator. The 11SI alternators have internal cooling fans.
BELT TENSIONING INSTRUCTIONS: DO NOT OVER TIGHTEN BELT! Improper belt tension can damage the alternator or cause the
bearings to fail later. If the belt must be tightened manually, pry only against the drive end (DE) frame. If that is not possible, use a wood
block with one end positioned against the DE frame between the pry bar and alternator. Use a torque wrench to tighten mounti ng bolts
to specified torque. Follow vehicle or engi
ne manufacturer’s specifications carefully for belt tension and mounting bolts torque.
[FIGURE 1]
WEATHER PACK CONVERSION ADAPTER KIT FOR
REPLACING 10SI, 12SI & BOSCH K1 WITH AN 11SI ALTERNATOR
INSTALLATION PROCEDURES
Determine the type of alternator this 11SI is replacing by checking the series type noted on the name tag of the alternator being
replaced. Follow instructions for that alternator as noted below.
Alternator Make / Model Figure
Delco Remy 11SI
2
Delco Remy 10SI
3
Delco Remy 12SI 4
Bosch K1 5
RELAY “R” RED LEAD
CONNECTOR
LAMP / IGNITION BLUE
LEAD CONNECTOR
VOLTAGE REGULATOR
CONNECTOR