Charging System - Generators & Regulators (All Except Hatchback): Overhaul Honda Civic VII

Disassembly

1. Test the alternator and regulator before you remove them. See «CHARGING SYSTEM INDICATOR TEST»(ref-153318-S29496244582004060900000) under TROUBLE SHOOTING.
2. Remove the alternator. See «ALTERNATOR»(ref-153318-S14361378742003071000000) under REMOVAL AND INSTALLATION.
3. Remove the 4 through bolts. (Scheme 9)
4. Heat the rear bearing seat with a 1,000 watt hair dryer for about 5 minutes (129-140°F (50-60°C). (Scheme 10)
5. Separate the rear housing from the drive-end housing by inserting a flat tip screwdriver into the openings and prying them apart. (Scheme 11)
6. Separate the rear housing "A" and drive-end housing "B" with the stator "C" attached to the rear housing. (Scheme 12)
7. If you are not replacing the front bearing and/or rear bearing, go to «BRUSHES»(ref-153318-S35262996792003040100000) under BENCH TESTING. Clamp the rotor in a soft-jawed vise, remove the pulley locknut. (Scheme 13)
8. Remove the rotor using a puller. (Scheme 14)
9. Inspect the rotor shaft for galling, 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 15)
11. Use a hand press to install the new rear bearing. Apply pressure only on the inner race to avoid damaging the bearing. (Scheme 16)
12. Remove the front bearing retainer plate. (Scheme 17)
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 18)

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Reassembly

1. If you removed the pulley, put the rotor in the drive-end housing. Tighten locknut to specification. See «TORQUE SPECIFICATIONS»(ref-153318-S21021060912003040100000).
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 19)
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 4 through bolts "C" and pull out the pin "D". (Scheme 20)
6. After assembling the alternator, turn the pulley by hand to ensure the rotor rotates smoothly and without noise.
7. Install the alternator and adjust its belt tension. See «ALTERNATOR»(ref-153318-S14361378742003071000000) under REMOVAL & INSTALLATION, and «ALTERNATOR BELT»(ref-153318-S27051005172004060900000) under ADJUSTMENT.

Scheme 20