Remy 36SI™ HD ALTERNATOR REPLACEMENT - Manual (Page 2)

NOTE: When referring to insulated models, the comments are underlined. Due to the complexity of the connections to the
regulator, replacement instructions below are separated for clarity.
1. Remove the RE cover to replace any of the terminal assemblies. It is important to note stack up of the individual parts on the
terminals prior to disassembly. All terminals are insulated from the RE frame.
DANGER!!! If all terminals are not kept insulated from the frame when the battery is connected, they can quickly get hot enough to
burn skin and damage surrounding parts.
2. It is advisable to remove and replace terminals one at a time, carefully noting parts stack up and where the straps and or leads
are connected. Torque requirements for the R, I & Sense terminals nuts are 1.7 - 2.8 Nm (15 - 20 lb in). The output (B+) terminal
torque is as follows: 1/4” is 5.7 - 6.8 Nm (50 - 60 lb in) M6 is 6.8 - 9.0 Nm (60 - 80 lb in) 5/16” is 7.4 - 11.1 Nm (65 - 98 lb in).
! DANGER!!! Incorrectly connecting the capacitor leads to the rectifier could result in damage or injury.
3. If replacing the capacitor (insulated models only), noting orientation, remove capacitor and replace as removed. Install and torque
bracket screw to 2.7 - 3.4 Nm (24 - 30 lb in) and numbers two (2) and three (3) terminals to 2.7 - 3.4 Nm (24 - 30 lb in).
WARNING!!! MULTIPLE STYLES OF SCREW ASSEMBLIES ARE USED INCLUDING INSULATED AND NON-INSULATED
SCREW ASSEMBLIES FOR REGULATORS AND RECTIFIER BRIDGES. THE SCREW ASSEMBLIES MUST BE REPLACED IN
THE SAME LOCATION AS REMOVED TO AVOID GROUNDING OR OTHER UNDESIREABLE RESULTS.
!
4. If replacing the regulator, remove the nut and all three (3) screw assemblies, carefully noting where leads and straps are
connected. The connections are as follows: F- [One (1) lead from field coil connected] GRD [Nothing is connected] F+ [One (1)
strap from P1 terminal, one (1) strap from “I” terminal and one (1) field coil lead are connected] Sense [one (1) lead from remote
sense terminal. It’s important to note if there are other straps or leads connected here because some models have a strap or lead
connected to #5 rectifier terminal].
5. Install new regulator and reconnect leads and straps as removed. Install and torque the three (3) screw assemblies to 1.8 - 2.3
Nm (16 - 20 lb in) and the nut assembly to 1.7 - 2 .8 Nm (15 - 25 lb in).
6. If replacing the diode trio, remove nut assemblies from P1 (R terminal lead is connected only on insulated models), P2, P3 (R
terminal strap is connected) and diode trio strap is connected to regulator F+ terminal. Also, note how the three (3) stator leads
connect to the P terminals. If replacing the stator and or field coil & support go to step 8 or 9.
7. Install new diode trio, stator leads and R-terminal strap. Be sure stator leads are all the way down on the bridge. Reinstall the
three (3) nut assemblies and torque to 1.7 - 2.8 Nm (15 - 25 lb in) and the strap to F+ terminal to 1.8 - 2.3 Nm (16 - 20 lb in).
8. If replacing the rectifier assembly, remove the rest of the terminals. 1 (POS terminal strap is connected. Torque screw
assembly to 1.8 - 2.3 Nm (16 - 20 lb in). 2 (insulated models have POS terminal strap and capacitor lead connected) 3
(insulated models have capacitor lead connected) 4 (insulated models have regulator GRD lead connected) 5 (carefully note
what is or is not connected between this and the regulator sense terminal because there several combinations).
9. If replacing the stator assembly, remove and dispose of stator assembly and install the new one, insuring the insulator is properly
placed in the slot. Go to installation step 1.
10. If replacing the field coil & support, remove the rectifier assembly and leads connected to the regulator. Remove the four (4)
mounting bolts and dispose of the coil assembly.
11. Install the new field coil and mounting bolts. Use a staggered pattern and torque the four (4) mounting bolts to 5.7 - 6.8 Nm (50 -
60 lb in). Reconnect leads to GRD & F- regulator terminals and torque to values noted in step 5. Go to installation step 1.
INSTALLATION INSTRUCTIONS
1. Replace or install new rectifier assembly and replace all straps and connectors as removed. See above steps for terminations and
torque requirements.
2. Assemble the DE and RE frames, being sure to line up the non-threaded mounting lugs or marks. This is best accomplished by
inserting a tolerance pin in the non-threaded holes on hinge mount (J180) units or 2 parallel blocks with pad mount units.
3. Install the four (4) thru bolts and torque to 50% of final value. Use a staggered sequence to finish and torque thru-bolts to
10.7 - 11.9 Nm (95 - 105 lb).
REINSTALL THE ALTERNATOR ACCORDING TO ENGINE OR VEHICLE MANFACTURERS INSTRUCTION’S
♦ Reattach the battery (+) terminal lead to alternator battery terminal and torque nut to 9.0-13.0 Nm (80 - 120 lb in).
♦ Reconnect the negative (-) cable at the battery.
REGULATOR TERMINAL CONNECTIONS FOR INSULATED MODELS
Remove the nut and all three (3) screw assemblies, carefully noting where leads and straps are
connected. The connections are as follows:
F- [One (1) field coil lead connected]
GRD (-) [One (1) lead from NEG (-) terminal connected. NOTE: There is also a lead (1) from the
NEG (-) terminal connected to the #4 rectifier terminal]
F+ [Some models have one (1) field coil lead, one (1) diode trio strap and one (1) remote sense
terminal strap connected. Other models do not have the remote sense connected here]
SENSE [Some models have a strap from #5 rectifier terminal. Other models have a lead from the remote sense terminal. NOTE:
When there is a remote sense lead connected, there is also one (1) lead from the remote sense terminal connected to the # 4 bridge
terminal]
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.
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2012 Remy International, Inc. All rights reserved 2 XXXXXXXX
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