Honda HR-V: Overhaul

ALTERNATOR OVERHAUL

Special Tools Required

Bearing Driver Attachment, 42 x 47 mm 07746-0010300

Driver Handle, 15 x 135L 07749-0010000

Exploded View

1. Alternator Exploded View

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

2. Terminal Insulator - Remove

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

1. Remove the four through bolts.

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

3. 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.

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

4. Stator - Remove

5. Stator - Inspect

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

7. Brush - Inspect

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)

2. 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

9. Rectifier - Inspect

Stator side

Rear housing side

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

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

11.Rotor - Remove

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

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

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

14.Front Bearing - Remove

1. Remove the front bearing retainer.

2. 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

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.

2. Install the front bearing retainer.

2. Rear Bearing - Install

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

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

4. Pulley - Install

Fig. 2: Alternator Pulley With Torque Specifications

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

5. Rectifier - Install

6. Voltage Regulator/Brush Holder Assembly - Install

7. Stator - Install

8. Drive-End Housing/Rotor Assembly - Install

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) ).

4. 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

10.Heat Shield and Bracket - Install

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