Generators & Regulators: Overhaul

NOTE: For overhaul, see exploded view of generator. See Fig 1

Fig 1: Exploded View Of Alternator (2.3L)

G97F11051

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 2: Exploded View Of Alternator (3.0L)

G99B05319

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Test the alternator and regulator before you remove them. See CHARGING SYSTEM INDICATOR TEST under TROUBLE SHOOTING.
Remove the alternator. See ALTERNATOR under REMOVAL & INSTALLATION.
If the front bearing needs replacing, remove the pulley locknut with a 10 mm wrench "A" and a 22 mm wrench "B". If necessary, use an impact wrench. See Fig 3.
Remove the three flange nuts "A" and the screw "B" from the alternator, then remove the plate terminal "C". See Fig 4for 2.3L or Fig 5 for 3.0L.
Remove the washer nut "A" and insulator "B" from the "B" terminal. Remove the end cover "C" and dust seal "D". See Fig 6 for 2.3L or Fig 7 for 3.0L.
Remove the brush holder. See Fig 8 for 2.3L or Fig 9 for 3.0L.
Remove the voltage regulator. See Fig 10 for 2.3L or Fig 11 for 3.0L.
Remove the 4 screws "A". Remove the rectifier "B" and rubber seal "C". See Fig 12 for 2.3L or Fig 13 for 3.0L.
Remove the 4 flange nuts. See Fig 14 for 2.3L or Fig 15 for 3.0L.1
Remove the 4 insulators "A" rear housing "B" and washer "C". See Fig 16.
If you are not replacing the front bearing and/or rear bearing, go to RECTIFIER under BENCH TESTING. Remove the rotor from the stator drive-end housing. See Fig 17.
Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the stator housing for seizure marks. If either the rotor or stator housing is damaged, replace the alternator. If both the rotor and the stator housing are OK, go to next step.
Remove the rear bearing using a puller. See Fig 18.
With a hammer, driver and attachment, install a new rear bearing in the rotor shaft. See Fig 19.
Remove the front bearing retainer plate. See Fig 20
Support the stator housing in a vise, and drive out the front bearing with a brass drift "A" and hammer.
Install a new front bearing in the stator housing. See Fig 21.

Fig 3: Removing Drive-End Housing Pulley Locknut

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Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 4: Removing Stator Drive-End Housing Components (2.3L)

G00302004

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 5: Removing Stator Drive-End Housing Components (3.0L)

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Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 6: Removing End Cover & Dust Seal (2.3L)

G00302002

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 7: Removing End Cover And Dust Seal (3.0L)

G00301970

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 8: Removing Brush Holder (2.3L)

G00302003

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 9: Removing Brush Holder (3.0L)

G00301972

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 10: Removing Voltage Regulator (2.3L)

G00302005

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 11: Removing Voltage Regulator (3.0L)

G00301973

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 12: Removing Rectifier And Rubber Seal (2.3L)

G00302006

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 13: Removing Rectifier And Rubber Seal (3.0L)

G00301974

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 14: Removing Flange Nuts (2.3L

G00302007

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 15: Removing Flange Nuts (3.0L)

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Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 16: Removing Rear Housing, Washer And Insulators

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Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 17: Removing Rotor From Stator Drive-End Housing

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Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 18: Removing Rear Bearing

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Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 19: Installing Rear Bearing

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Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 20: Removing Front Bearing Retainer Plate

G00301954

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Fig 21: Installing/Removing Front Bearing In Stator Housing

G00301977

Courtesy of AMERICAN HONDA MOTOR CO., INC.