Charging System - Generators & Regulators Acura RSX I

DESCRIPTION & OPERATION

Note. Vehicles equipped with a M/T use an Engine Control Module (ECM). Vehicles equipped with an A/T use a Powertrain Control Module (PCM). ECM may also be referred to as PCM.

COMPONENT LOCATION INDEX & DRIVE BELT ROUTING

For component location (Scheme 1)

Scheme 1

DRIVE BELT

Check that auto-tensioner indicator is within the standard range. (Scheme 2) If it is out of the standard range, replace the drive belt.

Scheme 2

CHARGING CIRCUIT

If the charging system indicator does not illuminate, or the battery is dead or low, test the following items in the order listed below

1. Battery
2. Charging system indicator
3. Alternator and regulator circuit
4. Alternator control system

Charging System Indicator Test (K20A3 Engine)

For charging indicator test (K20A3 Engine) see, (Scheme 3).

Scheme 3

Charging System Indicator Test (K20A2 Engine)

For charging indicator test (K20A2 Engine) see, (Scheme 4).

Scheme 4

Alternator And Regulator Circuit Test

For alternator and regulator test see, (Scheme 5).

Scheme 5

Alternator Control System Test (K20A3 Engine)

For alternator control system test (K20A3 Engine) see, (Scheme 6).

Scheme 6

Alternator Control System Test (K20A2 Engine)

For alternator control system test (K20A2 Engine) see, (Scheme 7).

Scheme 7

BRUSHES

Measure the length of both brushes with a vernier caliper. (Scheme 8)for K20A3 Engine (Scheme 9)for K20A2 Engine. If either brush is shorter than the service limit, replace the rear housing assembly. If brush length is OK, go to ROTOR SLIP RING TEST.

Scheme 8

Scheme 9

RECTIFIER

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 8 diodes (4 pairs), you must test each diode in both directions for continuity with an ohmmeter that has diode checking capability: a total of 16 checks. If any diode is faulty, replace the rectifier assembly (diodes are not available separately). If all the diodes are OK, go to BRUSHES .

Scheme 10

ROTOR SLIP RING

1. Check that there is continuity between the slip rings. If there is continuity, go to next step. If there is no continuity, replace the rotor assembly. (Scheme 11)
2. Check that there is no continuity between each slip ring and the rotor and the rotor shaft. If there is no continuity, go to «STATOR»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators__stator). If there is continuity, replace the alternator.

Scheme 11

STATOR

1. Check that there is continuity between each pair of leads. (Scheme 12) If there is continuity, go to next step. If there is no continuity, replace the alternator.
2. Check for no continuity between each lead and the coil core "B". If there is no continuity, go to next step. If there is continuity, replace the alternator.
3. Be careful not to get any grease or oil on the slip rings during reassembly.

Scheme 12

Removal

1. Ensure you have the anti-theft code the radio. Write down the frequencies for radio's preset buttons.
2. Disconnect the negative cable from the battery first. Disconnect the positive cable.
3. Remove the drive belt, see «DRIVE BELT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators).
4. Remove the auto-tensioner. See «DRIVE BELT AUTO-TENSIONER»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators).
5. Remove the three bolts securing the alternator. (Scheme 13).
6. Disconnect the alternator connector "A" and Black wire "B" from the alternator. (Scheme 14)
7. Remove the alternator.

Scheme 13

Scheme 14

Installation

1. Install the alternator and drive belt in the reverse order of removal.
2. Connect the positive cable and negative cable to the battery.
3. Enter the anti-theft code for the radio. Enter the customer's radio station presets.
4. Set the clock.
5. Perform the ECM PCM idle learn procedure, and the power window control unit reset procedure. See appropriate COMPUTER RELEARN article in GENERAL INFORMATION.

Removal & Installation

Unclip power steering reservoir. Move the auto-tensioner "A" to relieve tension from the drive belt "B", and remove drive belt. (Scheme 15) To install, reverse removal procedure.

Scheme 15

Inspection

1. Check whether there is a change in the position of the auto-tensioner indicator before starting the engine and after starting the engine. If there is a change in the position, replace the auto-tensioner. (Scheme 2)
2. Check for abnormal noise from the tensioner pulley. If abnormal noise is heard, replace the tensioner pulley.
3. Remove the drive belt. See «DRIVE BELT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators).
4. Move the auto-tensioner within its limit with the belt tension release tool in the direction shown. (Scheme 16) Check that the tensioner moves smoothly and without any abnormal noise. If the tensioner does not move smoothly or there is abnormal noise, replace the auto-tensioner.
5. Remove the auto-tensioner. (Scheme 20)under REPLACEMENT.
6. Install the tensioner pulley.
7. Clamp the auto-tensioner "A" by using two 8-mm bolts "B" and a vise "C". Do not clamp the auto-tensioner itself. (Scheme 17)
8. Set the torque wrench "D" on the pulley bolt.
9. Align the indicator "E" on the tensioner arm with center mark "F" on the tensioner base by using the torque wrench, and measure the torque. If the torque value is out of specification, replace the auto-tensioner.

Scheme 16

Scheme 17

Replacement

1. Remove the drive belt. See «DRIVE BELT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators).
2. Remove the Power Steering (P/S) pump without disconnecting the P/S hoses. (Scheme 18)
3. Remove the tensioner pulley. (Scheme 19)
4. Remove the auto-tensioner. (Scheme 20)
5. Install in the reverse order of removal.

Scheme 18

Scheme 19

Scheme 20

Disassembly (K20A3 Engine)

Use exploded view of alternator K20A3 engine for overhaul. (Scheme 21)

Scheme 21

1. Test the alternator and regulator before you remove them. See «CHARGING SYSTEM INDICATOR TEST (K20A3)»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators__charging-system-indicator-test-k20a3-engine) under TROUBLE SHOOTING.
2. Remove the alternator. See «ALTERNATOR»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators) under REMOVAL AND INSTALLATION.
3. Remove the 4 through bolts.
4. Heat the rear bearing seat with a 1,000 watt hair dryer for about 5 minutes (129-140°F (50-60°C). (Scheme 22)
5. Separate the rear housing from the drive-end housing by inserting a flat tip screwdriver into the openings and prying them apart. (Scheme 23)
6. Separate the rear housing "A" and drive-end housing "B" with the stator "C" attached to the rear housing. (Scheme 24)
7. If you are not replacing the front bearing and/or rear bearing, go to «BRUSHES»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators__brushes) under BENCH TESTING. Clamp the rotor in a soft-jawed vise, remove the pulley locknut. (Scheme 25)
8. Remove the rotor using a puller. (Scheme 26)
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 next step.
10. Remove the rear bearing using the puller. (Scheme 27)
11. Use a hand press to install the new rear bearing. Apply pressure only on the inner race to avoid damaging the bearing. (Scheme 28)
12. Remove the front bearing retainer plate. (Scheme 29)
13. Support the drive-end housing in a vise, and drive out the front bearing with a brass drift and hammer.
14. With a hammer, driver and attachment install a new front bearing in the drive-end housing. (Scheme 30)

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Reassembly

1. If you removed the pulley, put the rotor in the drive-end housing. Tighten locknut to specification. See «TORQUE SPECIFICATIONS»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators__torque-specifications).
2. Remove any grease or any oil from the slip rings.
3. Push the brushes "A" in. Insert a pin or drill bit "B".77" (1.8 mm diameter) to hold them there. (Scheme 31)
4. Heat the rear bearing seat with a 1,000 watt hair dryer for about 5 minutes (129-140°F (50-60°C).
5. 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". (Scheme 32)
6. After assembling the alternator, turn the pulley by hand to ensure the rotor rotates smoothly and without noise.
7. Install the alternator and drive belt. See «ALTERNATOR»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators) and «DRIVE BELT»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators) under REMOVAL & INSTALLATION.

Scheme 31

Scheme 32

Disassembly (K20A2 Engine)

Use exploded view of alternator K20A2 engine for overhaul. (Scheme 33)

Scheme 33

1. Test the alternator and regulator before you remove them. See «CHARGING SYSTEM INDICATOR TEST(K20A2 ENGINE)»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators__charging-system-indicator-test-k20a2-engine) under TROUBLE SHOOTING.
2. Remove the alternator. See «ALTERNATOR»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators) under REMOVAL AND INSTALLATION. (Scheme 14)
3. 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. (Scheme 34)
4. Remove the harness bracket "A", insulator "B", three flange nuts "C" and the screw "D", remove the plate terminal "E". (Scheme 35)
5. Remove the end cover "A" and dust seal "B". (Scheme 36)
6. Remove the brush holder "A", voltage regulator "B" and the rubber seal "C". (Scheme 37)
7. Remove the 4 screws. Remove the rectifier "A" and 4 insulators "B". (Scheme 38)
8. Remove the 4 flange nuts. Remove the rear housing "A" and washer "B". (Scheme 39)
9. If you are not replacing the front bearing and/or rear bearing, go to «RECTIFIER TEST»(/acura/rsx/i-2001-2004/remont/charging-system/#charging-system-generators-regulators__rectifier) under BENCH TESTING. Remove the rotor from the stator drive end housing. (Scheme 40)
10. 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.
11. Remove the rear bearing using a puller. (Scheme 27)
12. Install a new rear bearing on the rotor shaft. (Scheme 41)
13. Remove the front bearing retainer plate. (Scheme 42)
14. Support the stator housing in a vise, and drive out the front bearing with a brass drift and hammer.
15. With a hammer, driver and attachment, install a new front bearing in the stator housing. (Scheme 43)

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

GENERATOR SPECIFICATIONS

GENERATOR SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

WIRING DIAGRAMS

For wiring diagrams on 2002 models, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

For wiring diagrams on 2003 models, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

For wiring diagrams on 2004 models, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

See also:
• ROTOR SLIP RING TEST
• BRUSHES
• STATOR
• DRIVE BELT
• CHARGING SYSTEM INDICATOR TEST (K20A3)
• TORQUE SPECIFICATIONS
• CHARGING SYSTEM INDICATOR TEST(K20A2 ENGINE)
• RECTIFIER TEST