Alternator Overhaul
Exploded View
Special Tools Required
Handle driver( 07749-0010000)
Driver attachment, 52 x 55 mm( 07746-0010400)
NOTE: Refer to the Exploded View as needed during this procedure.
Test the alternator and regulator before you remove them.
3. | Remove the four through bolts.
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4. | Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (50-60°C, 129-140°F).
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5. | Separate the rear housing from the drive-end housing by inserting a flat tip screwdriver into the openings and prying them apart.
NOTE: Be careful not to damage the stator with the tip of the screwdriver.
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6. | Separate the rear housing (A) and drive-end housing (B) with the stator (C) attached to the rear housing.
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7. | If you are not replacing the front bearing and/or rear bearing, go to 15. Clamp the rotor in a soft-jawed vise, then remove the pulley locknut.
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8. | Remove the rotor using a puller as shown.
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9. | Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks.
- If either the rotor or drive-end housing is damaged, replace the alternator.
- If both the rotor and the drive-end housing are OK, go to 10.
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10. | Remove the rear bearing using the puller as shown.
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11. | Use a hand press to install the new rear bearing. Apply pressure only on the inner race to avoid damaging the bearing.
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12. | Remove the front bearing retainer plate.
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13. | Support the drive-end housing in a vise, and drive out the front bearing with a brass drift (A) and hammer.
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14. | With a hammer and the special tools, install a new front bearing in the drive-end housing.
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Alternator Brush Inspection
15. | Measure the length of both brushes with a vernier caliper.
- If either brush is shorter than the service limit, replace the rear housing assembly.
- If brush length is OK, go to 16.
Alternator Brush Length:Standard (New): | 19.0 mm (0.75 in.) | Service Limit: | 5 mm (0.2 in.) | |
Rotor Slip Ring Test
16. | Check that there is continuity between the slip rings (A).
- If there is continuity, go to 17.
- If there is no continuity, replace the rotor assembly.
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17. | Check that there is no continuity between each slip ring (A) and the rotor (B) and the rotor shaft (C).
- If there is no continuity, replace the rear housing assembly, go to 18.
- If there is continuity, replace the rotor assembly.
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Alternator Reassembly
18. | If you removed the pulley, put the rotor in the drive-end housing, then tighten its locknut to 111 N·m (11.3 kgf·m, 81.7 lbf·ft).
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19. | Remove any grease or any oil from the slip rings.
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20. | Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.8 mm (0.77 in.) diameter) to hold them there.
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21. | Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (50-60°C, 129-140°F).
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22. | Put the rear housing assembly (A) and drive-end housing/rotor assembly (B) together, tighten the four through bolts (C) and pull out the pin (D).
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23. | After assembling the alternator, turn the pulley by hand to make sure the rotor rotates smoothly and without noise.
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Honda Fit/Jazz 02-05 Workshop Manual
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