Delco-Remy Compact Alternator, Disassemble and Assemble
Delco-Remy Compact Alternator, Disassemble and Assemble
Important!
Before disassembling the alternator, mark position of the casing front and rear parts with respect to the stator. Do not damage leading-out wire of the stator winding.
Disassemble
Release fastening nut for pulley - counterhold pulley with flat wrench. Remove pulley and spacer washer from armature shaft.
Release fastening bolts (1) from housing cover. Remove housing cover from alternator.
Unscrew capacitor from brush holder (2).
Disassemble
Disconnect plug connection between brush holder and electronic regulator.
Release fastening bolt (1) from brush holder.
Lift carbon brushes from slip rings and remove brush holder from housing.
Important!
Do not damage carbon brushes and slip rings when removing brush holder!
Disassemble
Release fastening bolts (1) from electronic regulator - note different bolts.
Unsolder solder joint between electronic regulator and rectifier bridge and remove electronic regulator.
Important!
To prevent overheating of diodes during the unsoldering process, grasp connecting cable with flat pliers - heat is then conducted better.
Disassemble
Release fastening bolts (2) from rectifier bridge.
Disassemble
Unsolder solder joint between rectifier bridge and stator winding and remove rectifier bridge.
Important!
To prevent the diodes from overheating during unsoldering, hold connection cable with flat-nosed pliers - this enables better heat dissipation.
Disassemble
Detach insulation from winding ends - mark position of housing halves with respect to one another.
Disassemble
Unscrew through-bolts (1) from alternator.
Remove rear housing half with stator winding and armature shaft from front housing half.
Remove spacer washer (2) and fan pulley (3) from armature shaft.
Disassemble
Remove stator winding from rear housing half.
Place housing on suitable rest. Press out armature shaft with dust cap and bearing (arrows).
Important!
Detach bearing from the armature shaft only if defective. Bearings detached from the armature shaft must not be reused.
Disassemble
Remove dust cap and bearing with bearing puller from armature shaft.
Assemble
Place armature shaft on suitable rest. Place dust cap (1) and bearing (2) on armature shaft.
Press on dust cap and bearing with suitable sleeve to stop on insulator (arrows).
Important!
The insulator will be damaged with an excessively large contact force.
Assemble
Push armature shaft by hand into rear housing half, supporting housing.
Important!
Ensure fan pulley does not touch housing!
Assemble
Insert stator winding in rear housing half.
Slide insulation onto winding ends - note installation position of insulation.
Install spacer washer and fan pulley on armature shaft.
Important!
Ensure that the retaining lugs of the fan wheel are seated in the recesses of the claw-pole armature (see magnification).
Assemble
Join front housing half with bearing and rear housing half - note mark for housing halves with respect to one another.
Insert through bolts (1) into alternator and screw housing halves together - 9.5 Nm / 7 lbf. ft.
Fit spacer washer and pulley onto armature shaft - counterhold pulley with flat wrench - tightening torque 80 Nm / 59 lbf. ft.
Assemble
Before installation of rectifier bridge:
- Bend contact tabs (1) slightly open.
- Coat rectifier bridge with heat conduction paste.
Important!
To prevent the diodes from overheating during soldering, hold connection cable with flat-nosed pliers - this enables better heat dissipation.
Assemble
Loosely bolt on rectifier bridge and solder contact tabs to winding ends.
Tighten fastening bolts (2) for rectifier bridge.
Assemble
Solder connection between electronic regulator and rectifier bridge.
Important!
To prevent the diodes from overheating during soldering, hold connection cable with flat-nosed pliers - this enables better heat dissipation.
Assemble
Bolt electronic regulator to housing bolt - use insulated fastening bolt (arrow) for regulator and rectifier bridge.
Lift carbon brushes during installation of brush holder with suitable tool.
Important!
Do not damage carbon brushes and slip ring when installing brush holder!
Assemble
Bolt brush holder using fastening bolt (1) onto housing.
Connect plug connection between brush holder and electronic regulator (arrow).
Place capacitor on terminal B+/30 (2) and bolt to brush holder (3).
Important! 
Disassemble 
Assemble 
