Remy 42MT Conventional Solenoid - Manual

Instruction Sheet
10511636
09SE13 C/P30500 REV5
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
37MT ™, 41MT™ & 42MT ™ CONVENTIONAL SOLENOID REPLACEMENT INSTRUCTIONS
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 STARTING MOTORS.
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.
FOLLOW ENGINE AND/OR VEHICLE MANUFACTURER'S INSTRUCTIONS CAREFULLY WHEN REMOVING AND INSTALLING
THE STARTER.
DISASSEMBLY PROCEDURES FOR REPLACING CONVENTIONAL SOLENOIDS
DANGER!!! ALWAYS DISCONNECT BATTERY GROUND BEFORE REMOVING OR REPLACING CABLES AT THE STARTER.
FAILURE TO DISCONNECT THE BATTERY GROUND CABLE CAN LEAD TO SERIOUS INJURY.
1. Remove vehicle leads connected to the starter, noting their positions for reinstallation of starter, and remove starter.
2. Disconnect solenoid-to-motor field connector strap.
3. Remove ground lead from solenoid terminal.
4. Remove the access plug and gasket from front of lever housing, ensuring the gasket is removed
5. Remove the three (3) solenoid mounting screws and the old solenoid. If the plunger return spring comes off with the
solenoid, replace it.
REASSEMBLY PROCEDURES FOR REPLACING THE CONVENTIONAL SOLENOIDS
1. Install new solenoid on the lever housing with the three (3) mounting screws. Torque mounting screws to 14.1-21.4 Nm (10-16 lb
ft).
2. Reattach the ground lead to the solenoid ground terminal and torque nut to 1.8-4.3 Nm (16-38 lb in).
3.
DANGER!!! Do not reconnect solenoid motor connector strap to field terminal before adjusting the pinion clearance.
After repair and reassembly, it is necessary before installation on the engine to check and adjust pinion clearance. (See
graphics, page 2)
4. Reinstall access plug and gasket in front of the lever housing and torque plug to a minimum of 8.1 Nm (72 lb in).
5. Reinstall solenoid-to-motor field connector strap. Reinstall field terminal and solenoid motor terminal screws finger tight.
6. Torque field terminal and solenoid motor terminal screws to 8.5-10.7 Nm (75-95 lb in).
7. For insulated models, remove top nut and washer assembly from the solenoid ground terminal and install flexible ground cable.
8. Install ground terminal nut and washer assembly and tighten to 1.8-4.3 Nm (16-38 lb in).
9. Reinstall starter and connect cables and other leads, as removed.
10. Reconnect the negative (-) cable at the batteries
Following these steps carefully is important for adjusting pinion clearance.
Proper care must be exercised when completing these steps to avoid personal injury and/or property damage. Also,
to avoid overheating and possible damage to the solenoid, power should not be applied in excess of one minute.
 DANGER!!! Ensure the stamped metal connector strap is disconnected from the field terminal to prevent the
possibility of motor from rotating.
 Energize solenoid to prevent plunger from rotating and damaging the rubber boot while turning plunger nut to adjust pinion
clearance.
 Apply appropriate power (12V or 24V) to solenoid between th e switch "S" (+) and “G” ground (-) terminals.
 Seat the plunger by simultaneously pushing on 1/2" plunger nut. Note: 24 volts can be obtained by connecting two 12V
batteries in series.
 Adjust plunger nut to obtain the pinion clearance defined based on the motor series being worked on. (See graphics on page
2)
 Remove power immediately after adjustment is completed.