Remy 42MT Upgrade from Standard to OCP User Manual

Remy Generators

Instruction Sheet

10533485

04OC13 REV4

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.
©

CUP &

WICK

42MT

™ STARTER UPGRADE FROM STANDARD (TYPE 400) TO OVER CRANK PROTECTION (TYPE 450) INSTRUCTIONS

NOTE: It is beneficial and possibly necessary to obtain 400 to 450 type upgrade service parts kit, for reassembly of the starter. It is

preferable to use new, undamaged parts.

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. A professional installation specialist should handle

mechanical repairs that are beyond your technical capabilities.

FOLLOW ENGINE AND/OR VEHICLE MANUFACTURER'S INSTRUCTIONS CAREFULLY WHEN REMOVING AND INSTALLING

THE STARTER.

DISASSEMBLY PROCEDURES TO UPGRADE STARTER TO OCP TYPE 450

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.

Remove vehicle leads connected to the starter,
noting their positions for reinstallation, and remove
starter.

Note position of the ground stud for reassembly.

From the insulated/ground terminal, carefully
noting orientation, remove all parts including the
solenoid ground lead. Check the condition of
insulators and sealing features and consider
replacing them if they are damaged or excessively
worn.

Remove the four (4) CE screws and CE housing. If
the armature thrust washer is stuck to the CE
housing hub, remove and replace it on the armature shaft. Dispose of the CE Housing.

Remove the remaining insulators from the ground stud, carefully noting orientation for reassembly. Check the condition of insulators
and sealing features and consider replacing them if they are damaged or excessively worn.

Remove the two (2) negative brush screws and remove the ground terminal and lead assembly. Dispose of the lead assembly.

REASSEMBLY PROCEDURES TO UPGRADE STARTER TO OCP TYPE 450

Install new ground terminal and lead assembly with thermostat. Attach the terminal’s negative leads and negative brush leads to the
brush plate with two (2) screws. Torque the screws to 2.3-4.5 Nm (20-40 lb in).

2. Install the square fiber insulator and fiber washer onto the ground stud.
3.

Apply bearing type grease onto inside diameter of new CE housing where the frame o’ring is seated and on the o’ring of the OCP
connector or on the inside diameter of the hole for the OCP in CE frame for easier assembly. Also, apply a small amount of SAE20
oil into the bushing area.

4. Install new CE housing over the locator pins and assure the square fiber washer is properly aligned with the anti-turn feature on the

CE housing.

5. Assure the thermostat connector is pulled through the CE frame far enough that you can see the retaining clip groove on the

connector.

6. Install the four (4) CE housing screws and torque to 4.5-6.8 Nm (40-60 lb in).
7. First insert the small round fiber insulator and then the rubber bushing over the Insulated/ground stud into the hole in the CE housing.

Installing the rubber bushing prior to installing the housing can pinch the bushing and destroy the sealing capabilities.

8. Install the large round fiber washer and remaining parts in the same order as were removed. Torque large nut on the ground stud to

27.0-33.8 Nm (20-25 lb ft).

9. Install clip on OCP connector.

NOTICE! After repair and reassembly it is necessary, before installation on the engine, to check and adjust pinion clearance.
It is recommended the solenoid replacement instruction sheet, be obtained from our website, www.delcoremy.com.

FOLLOW ENGINE AND/OR VEHICLE MANUFACTURER'S INSTRUCTIONS CAREFULLY WHEN REMOVING AND INSTALLING
THE STARTER.