Delco 10/12/15 SI Modification Instructions

The purpose of this modification is to allow the MOBI-ARC’s PWM regulator to control the alternator. The Delco’s regulator will be removed and a provision for external regulation will be made. By removing the 10-Pin wire harness from the back of the control unit and connecting the BYPASS plug, the Delco’s regulator is restored to its original working condition allowing standard regulation of the alternator without the control unit present. Read through these pages before undertaking modification. People not mechanically inclined may choose to have a local alternator re-builder facilitate this modification. Parts required for modification: D1-1604 Dummy Regulator External Regulator F540E

Brush holder module (not provided-already in alternator)

Remover four (4) thru-bolts and separate the front housing from rear housing. This may require tapping on the front housing with a rubber mallet. As the brushes are spring loaded, be sure that you don't lose the springs as you separate the two halves of the alternator.

BRUSH HOLDER

Unscrew the three (3) nuts

as illustrated by the arrows. This will allow the removal of the stator, giving us plenty of room to work.

Once separation is complete, lay the alternator on a flat surface and be sure no transient debris is present. The inside of your alternator should look similar to the picture on the right, however, your carbon brushes will be exposed from the brush-holder. We've reloaded the brushes in the picture to give you a better view.

With the stator removed, unscrew the three screws identified in the above picture.

Once the screws are removed, carefully remove the brush-holder, diode trio, resistor, and regulator. The picture below illustrates what those components look like. The diode trio, resistor, and regulator will not be

used in this configuration.

RESISTOR BRUSH HOLDER DIODE TRIO

REGULATOR

.

Dummy regulator module

Set of Blue and Green Field wire placement

Brush-holder placed on top on Dummy Regulator. Blue and Green field wires get placed between the Brush-holder and the Dummy Regulator. Note the screws with insulators.

Insulator

Insulator

No Insulator

Alternator with components removed and the dummy regulator module is seated

Route wires carefully away from moving parts. Add silicone where necessary.

ANY VARIATION IN CONFIGURATION MAY CAUSE THE SPINNING ROTOR TO CONTACT STATIONARY PARTS CAUSING ALTERNATOR FAILURE

Be sure to push Brush-holder Retention Pin through rear housing so it can easily be removed once alternator is closed.

Replace stator and re-attach stator nuts

SCREWS

WIRES TUCKED INSULATED BRUSH-HOLDER RETENTION WIRE

WHEN YOU ARE SURE ALL WIRES HAVE BEEN TUCKED OUT OF THE WAY AND YOUR

ALTERNATOR LOOKS EXACTLY LIKE THE PICTURES ON THE PREVIOUS PAGES, BLOW OUT THE ALTERNATOR TO REMOVE ANY DEBRIS. DROP THE FRONT HOUSING IN PLACE TAKING

CARE TO LINE UP THRU-BOLT HOLES, THEN REPLACE AND TIGHTEN THRU-BOLTS.

GIVE THE ALTERNATOR A SPIN BY HAND AND LISTEN FOR ROTOR CONTACT AGAINST STATIONARY PARTS (NOTE—IF THE BRUSH RETENTION WIRE STICKS IN TOO FAR, THE ROTOR

COULD CONTACT IT)

REMOVE BRUSH RETENTION WIRE

The modification is now complete. The BYPASS plug will hang loose from external regulator. Should the MOBI-ARC Control Unit malfunction or be moved to a different vehicle, the BYPASS plug will connect to the

10-Pin wiring harness. See the BYPASS instructions for more detail.

When installing the alternator, adhere to the appropriate belt tension as specified by the vehicle’s manufacturer. Once installed, the original BATTERY OUTPUT Cable will not be used. Insulate and secure from moving parts. The original alternator harness will not be used.