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Instruction Sheet 10500196 24AP17 CN02146 REV8

33SI, 34SI, 35SI & 36SI ALTERNATOR INSTALLATION INSTRUCTIONS
Instructions include installing or upgrading 21SI, 22SI, 23SI, 24SI, 33SI & 34SI alternators to a 35/36SI HP with remote senseTM technology for improved battery monitoring and charging performance.

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? ALTERNATORS. FAILURE TO USE PROPER EYE PROTECTION CAN LEAD TO SERIOUS AND PERMANENT EYE DAMAGE.

DANGER!!! To avoid injury or damage, always disconnect the negative cable at the battery before removing or replacing the alternator. The alternator output terminal is always live (“hot”). If the battery is not disconnected, a tool accidentally
Touching this terminal and ground can quickly get hot enough to burn skin or damage to the tools and surrounding parts.

FOLLOW ENGINE OR VEHICLE MANUFACTURER’S INSTRUCTIONS FOR REMOVING THE OLD ALTERNATOR FROM THE ENGINE AND INSTALLING THE NEW ALTERNATOR.

PULLEY INSTRUCTIONS: Use pulley from old alternator if this alternator does not have a pulley or pulley supplied is different from the one on alternator being replaced. NOTICE! When changing the pulley, keep the alternator in the horizontal position and do not apply any pressure to end of the shaft. Internal damage will occur if the shaft is pushed back and turned. If there were spacers, when the fan and pulley were removed, make sure all spacers are replaced when installing the fan and pulley on these alternators. Hold theshaftbyplacingan8.01mm(5/16”)hexwrenchinthehexagonalholeintheshaftwhileremovingorinstallingthepulley. Tighten the pulley nut to 95-108 Nm (70-80 lb ft).

BELT TENSIONING INSTRUCTIONS: Improper belt tension can cause premature alternator failure. If the belt must be tightened manually, place a wood block between the alternator and pry bar (See illustration). Pry as close to the center of the unit as possible. Use a torque wrench to tighten mounting bolts to specified torque. Follow vehicle or engine manufacturer’s specifications carefully for belt tension and mounting bolts torque. DO NOT OVER TIGHTEN BELT!

REMOVAL & INSTALLATION INSTRUCTIONS (See illustrations, page 2):

• ?  Disconnect the negative (-) cable at the batteries.

• ?  NOTE: Replacing units that are remote sense equipped remove both positive (+) and negative (-) cables from batteries. Failure to remove the positive cable can cause internal damage when the B+ termination is installed first and the remote sense lead is allowed to touch ground (alternator case).

• ?  Identify and tag all leads when removing the old Alternator and install them on the same terminals of the new Alternator.

• ?  Some 21SI, 22SI and 24SI applications may require enlarging the ring terminals. Others will require cutting and terminating wiring for

  one or all of the “I”, “R” and “Remote Sense” leads.

• ?  Cut lead, strip insulation 1/2”, insert wire into an A 3 Amp or equivalent ring terminal, crimp and solder the wire.

• ?  Insure all leads are hooked back up or contained where they cannot become grounded.

• ?  Torque all fasteners to values labeled on the illustration (page 2).

• ?  This alternator may have more terminals than the one being replaced had or used. It will charge properly with only the battery and

  ground leads connected. Use of the other terminals is optional based on need. See “TERMINAL DESCRIPTIONS”, Page 2.

  NOTE: There may be applications where it is necessary to add a jumper wire between the remote sense terminal and the battery (+) terminal on the alternator to lower the output voltage for 34SI, 35SI & 36SI alternators. If necessary, use an 18 AWG minimum wire size terminated with ring terminals to fit remote sense and battery (B+). Securely crimp and solder the connections.