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
®
.
21SI™ & 22SI™ HD ALTERNATOR REPLACEMENT COMPONENTS INSTRUCTIONS
These instructions explain how to remove and replace serviceable components for these 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
®
ALTERNATORS. FAILURE TO
USE PROPER EYEPROTECTION 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 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.
DIASSEMBLY INSTRUCTIONS FOR DRIVE END (DE) FRAME COMPONENTS - FAN - ROTOR - DE FRAME (WITH BEARING) - DE
BEARING - BEARING RETAINER
REFERENCE: There is an exploded parts view of these alternators for easy reference on page 3. Exploded views can be found on the
www.delcoremy.com web site under product support for these alternators and other products.
NOTE: Some components can be removed without following all steps as sequenced.
1. Remove the pulley nut, pulley and fan. If replacing one of these parts, dispose of it and install replacement. Torque the pulley nut
to 95-108 Nm (70-80 lb ft).
NOTICE!! Excessive movement of stator may weaken or break a lead or leads between the stator and rectifier assemblies.
2. If replacing the rotor, DE frame, DE bearing or retainer plate, remove the DE frame and rotor assembly, by removing the four (4)
thru-bolts (mark end frames for reassembly) that hold the end frames together.
3. Separate the rotor assembly from the DE frame, using a press. If replacing rotor, dispose of it and press replacement rotor with
spacer into DE frame.
NOTICE!!! It is recommended the DE and SRE bearings be replaced when replacing the rotor assembly.
4. If replacing DE frame (with bearing), dispose of it and press rotor assembly and spacer into replacement DE frame (with bearing).
5. If replacing DE bearing, remove the three (3) retainer plate screw assemblies and retainer plate. Using a press, remove and
dispose of the old bearing and press new bearing into frame bore until seated, by applying force against the outer race only.
6. Reinstall or replace the bearing retainer plate and screws. Torque the three (3) retainer screws to 4.5 - 5.7 Nm (40 - 50 lb in).
7. Go to component assembly instructions, page 2.
DISASSEMBLY INSTRUCTIONS FOR SRE FRAME COMPONENTS - STATOR - TERMINAL PACKAGES - DIODE TRIO OR DIODE
TRIO & AUTO START - REGULATOR – RECTIFIER BRIDGE – STATOR - SRE FRAME
REFERENCE: There is an exploded parts view of these alternators for easy reference on page 3. Exploded views can be found on the
www.delcoremy.com web site under product support for these alternators and other products.
21S & 22SI VOLTAGE REGULATOR 21SI & 22SI RECTIFIER BRIDGE
The regulator and rectifier terminals are labeled to better enable following instructions for replacing components and parts.
NOTE: Some components can be removed without following all steps as sequenced.
1. Remove the DE frame and rotor assembly, by removing the four (4) thru-bolts (mark end frames for reassembly) that hold the end
frames together and separate the end frames.
2. If replacing the stator, remove the three (3) nut assemblies from the P1, P2 and P3 rectifier terminals, noting position of leads for
reassembly. Install replacement stator, making sure leads are all the way down on the terminals, and three (3) nut assemblies.
Torque nuts to 1.7-2.8 Nm (15-25 lb in).
.
10539632
25NO13 DS07927 REV0
FOLLOW ENGINE OR VEHICLE MANFACTURERS INSTRUCTION’S CAREFULLY WHEN REMOVING AND REINSTALLING THE
ALTERNATOR.
♦ Disconnect the negative (-) cable at the batteries.
♦ Remove vehicle leads connected to the alternator, noting their positions for reinstallation of the alternator.
(7 pages)
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