Honda HR-V Owners & Service Manuals

Honda HR-V: Overhaul

ALTERNATOR OVERHAUL

Special Tools Required

Bearing Driver Attachment, 42 x 47 mm 07746-0010300

Charging System - Overhaul, Testing & Troubleshooting

Driver Handle, 15 x 135L 07749-0010000

Charging System - Overhaul, Testing & Troubleshooting

Exploded View

1. Alternator Exploded View

Charging System - Overhaul, Testing & Troubleshooting
Fig. 1: Alternator Exploded View With Torque Specifications

Disassembly

NOTE: Refer to the Exploded View if needed during this procedure.

1. Heat Shield and Bracket - Remove

Charging System - Overhaul, Testing & Troubleshooting

2. Terminal Insulator - Remove

Charging System - Overhaul, Testing & Troubleshooting

3. Rear Housing/Stator Assembly and Drive-End Housing/Rotor Assembly - Separate

Charging System - Overhaul, Testing & Troubleshooting

  1. Remove the four through bolts.

Charging System - Overhaul, Testing & Troubleshooting

  1. Heat the rear bearing seat with a heat gun for about 5 minutes (122-140ºF (50-60ºC) ).

Charging System - Overhaul, Testing & Troubleshooting

  1. 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.

Charging System - Overhaul, Testing & Troubleshooting

  1. Separate the rear housing/the stator assembly (A) and the drive-end housing/the rotor assembly (B).

4. Stator - Remove

Charging System - Overhaul, Testing & Troubleshooting

5. Stator - Inspect

Charging System - Overhaul, Testing & Troubleshooting

  1. Check for continuity between each lead (A). If there is no continuity, replace the stator
  2. Check for continuity between each lead and the coil core (B). If there is continuity, replace the stator.

6. Voltage Regulator/Brush Holder Assembly - Remove

Charging System - Overhaul, Testing & Troubleshooting

7. Brush - Inspect

Charging System - Overhaul, Testing & Troubleshooting

  1. Measure the length of both brushes with a vernier caliper. If either brush is shorter than the service limit, replace the brushes, go to step 2.

Standard (New): 23 mm (0.91 in)

Service Limit: 5 mm (0.20 in)

Charging System - Overhaul, Testing & Troubleshooting

  1. Unsolder the brush leads from the voltage regulator/brush holder assembly with a 100 W soldering iron (A), then replace the brushes.

8. Rectifier - Remove

Charging System - Overhaul, Testing & Troubleshooting

9. Rectifier - Inspect

Stator side

Charging System - Overhaul, Testing & Troubleshooting

Rear housing side

Charging System - Overhaul, Testing & Troubleshooting

  1. Check for continuity in each direction, between the B terminal and P terminals, and between the E terminal and P terminals of each diode pair. All diodes should have continuity in only one direction. Because the rectifier diodes are designed to allow current to pass in one direction, and the rectifier is made up of six diodes (six pairs), you must test each diode in both directions for continuity with an ohmmeter that has diode checking capability: a total of 24 checks. If any diode fails, replace the rectifier assembly. (Diodes are not available separately.)

10.Pulley - Remove

Charging System - Overhaul, Testing & Troubleshooting

  1. Clamp the rotor in a soft-jawed vise
  2. Remove the pulley nut, then remove the pulley.

11.Rotor - Remove

Charging System - Overhaul, Testing & Troubleshooting

  1. Remove the rotor using a puller as shown
  2. Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks.

    NOTE : If either the rotor or drive-end housing is damaged, replace the alternator.

12.Rotor Slip Ring - Test

Charging System - Overhaul, Testing & Troubleshooting

  1. Check for continuity between the slip rings (A):
    • If there is continuity, go to step 2.
    • If there is no continuity, replace the rotor assembly.
  2. Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C):
    • If there is no continuity, replace the rear housing assembly.
    • If there is continuity, replace the rotor assembly.

13.Rear Bearing - Remove

Charging System - Overhaul, Testing & Troubleshooting

  1. Remove the rear bearing using the puller as shown.

14.Front Bearing - Remove

Charging System - Overhaul, Testing & Troubleshooting

  1. Remove the front bearing retainer.

Charging System - Overhaul, Testing & Troubleshooting

  1. Drive out the front bearing with a brass drift and a hammer.

Reassembly

NOTE: Refer to the Exploded View if needed during this procedure.

1. Front Bearing - Install

Charging System - Overhaul, Testing & Troubleshooting

  1. Install a new front bearing in the drive-end housing with a hammer, the driver handle, 15 x 135L, and the attachment, 42 x 47 mm.

Charging System - Overhaul, Testing & Troubleshooting

  1. Install the front bearing retainer.

2. Rear Bearing - Install

Charging System - Overhaul, Testing & Troubleshooting

  1. Use a hand press to install a new rear bearing. Apply pressure only on the inner race to avoid damaging the bearing.

3. Rotor - Install

Charging System - Overhaul, Testing & Troubleshooting

  1. Install the spacer (A) and the rotor (B).

4. Pulley - Install

Charging System - Overhaul, Testing & Troubleshooting
Fig. 2: Alternator Pulley With Torque Specifications

  1. Clamp the rotor in a soft-jawed vise
  2. Install the pulley.

5. Rectifier - Install

Charging System - Overhaul, Testing & Troubleshooting

6. Voltage Regulator/Brush Holder Assembly - Install

Charging System - Overhaul, Testing & Troubleshooting

7. Stator - Install

Charging System - Overhaul, Testing & Troubleshooting

8. Drive-End Housing/Rotor Assembly - Install

Charging System - Overhaul, Testing & Troubleshooting

  1. Remove any grease or oil from the slip rings
  2. Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.8 mm (1/16 in) diameter) to hold them in place
  3. Heat the rear bearing seat with a heat gun for about 5 minutes (122-140ºF (50-60ºC) ).

Charging System - Overhaul, Testing & Troubleshooting

  1. Put the rear housing assembly (A) and the drive-end housing/rotor assembly (B) together, tighten the four through bolts, and pull out the pin (C).

9. Terminal Insulator - Install

Charging System - Overhaul, Testing & Troubleshooting

10.Heat Shield and Bracket - Install

Charging System - Overhaul, Testing & Troubleshooting

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