Delco-Remy compact alternator, disassemble and assemble
Delco-Remy Compact Alternator, Disassemble and Assemble
Important!
Before disassembling the alternator, mark position of the housing front and rear parts relative to the stator. Do not damage winding end of the stator winding.
Disassemble
Loosen pulley nut. Remove pulley and spacer washer from armature shaft.
Counterhold pulley with strap wrench.
Loosen bolts from housing cover (1). Remove housing cover from alternator.
Unscrew capacitor from brush holder (2).
Disassemble
Loosen plug connection between brush holder and electronic regulator.
Loosen bolt from brush holder (1).
Lift carbon brushes from scraper rings and remove brush holder from housing.
Important!
When removing the brush holders, do not damage carbon brushes and scraper rings!
Disassemble
Loosen bolts from electronic regulator (1).
Note different bolts!
Unsolder solder connection between electronic regulator and rectifier bridge. Remove electronic regulator.
Important!
To prevent overheating of diodes during the unsoldering process, grasp connecting cable with flat pliers - heat is then conducted.
Loosen bolts from rectifier bridge (2).
Disassemble
Unsolder rectifier bridge from stator winding. Remove rectifier bridge.
Important!
To prevent overheating of diodes during the unsoldering process, grasp connecting cable with flat pliers - heat is then conducted.
Remove insulation from winding ends.
Mark relative positions of housing halves.
Disassemble
Unscrew through bolts from alternator (1).
Remove rear housing half with stator winding and armature shaft from front housing half.
Remove spacer washer (2) and fan wheel (3) from armature shaft.
Disassemble
Take stator winding from rear housing half.
Place housing on suitable support. Press out armature shaft with dust guard and bearing (arrows).
Remove bearing from the armature shaft only if defective. Do not re-install bearing removed from armature shaft.
Remove dust guard and bearing with clawed puller from the armature shaft.
Assemble
Place armature shaft on suitable support. Install dust guard (1) and bearing (2) on armature shaft.
Press on dust guard and bearing with suitable sleeve up to stop at insulator (arrows).
Important!
Excessive contact pressure damages insulator!
Assemble
Press armature shaft by hand into rear housing half, supporting housing.
Important!
Ensure that the fan wheel does not scrape against housing!
Assemble
Insert stator winding in rear housing half.
Slide insulation on winding ends.
Note installation position of insulation.
Install spacer washer and fan wheel onto armature shaft.
Ensure that the retaining lugs of the fan wheel are seated in the recesses of the claw-pole armature (see section).
Assemble
Join front housing half with bearing and rear housing half.
Note markings of housing halves relative to one another.
Insert through bolts (1) in alternator and screw housing halves together - 9.5 Nm/7 lbf. ft.
Assemble spacer washer and pulley on armature shaft. Counterhold pulley with commercially available strap wrench - 80 Nm/59 lbf. ft.
Assemble
Before installing rectifier bridge:
-
Slightly bend up contact tabs (1)
-
Coat rectifier bridge with heat conducting paste.
Important!
To prevent overheating of diodes during the unsoldering process, grasp connecting cable with flat pliers - heat is then conducted.
Loosely screw on rectifier bridge (2). Solder contact tabs with winding ends.
Assemble
Tighten bolts from rectifier bridge (2).
Assemble
Solder connection between electronic regulator and rectifier bridge.
Important!
To prevent overheating of diodes during the unsoldering process, grasp connecting cable with flat pliers - heat is then conducted.
Assemble
Electronic regulator to housing bolt. Use insulated bolt for regulator and rectifier bridge (arrow).
When installing the brush holders, lift carbon brushes with suitable tool.
Important!
When installing the brush holders, do not damage carbon brushes and scraper rings!
Assemble
Screw brush holder to housing (1).
Connect plug connection between brush holder and electronic regulator (arrow).
Install capacitor at terminal B+/30 (2) and screw to brush holder (3).
Important! 
Disassemble 
Assemble 
