Generators & Regulators: Overhaul Honda Pilot I

OVERHAUL

Note. Use exploded view of generator for overhaul. (Scheme 11)

Scheme 11

1. Test the alternator and regulator before you remove them. See «CHARGING SYSTEM INDICATOR TEST»(ref-162803-S00115908972004061000000) under TROUBLE SHOOTING.
2. Remove the alternator. See «ALTERNATOR»(ref-162803-S23346743602004061000000) under REMOVAL & INSTALLATION.
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 12)
4. Remove the 3 flange nuts and the terminal insulator from the alternator. (Scheme 13)
5. Remove the end cover "A" and seal ring "B". (Scheme 14)
6. Remove the brush holder assembly "A" and seal ring "B". (Scheme 15)
7. Remove 4 bolts. Remove the rear housing assembly "A", washer "B", and rear bearing cover "C". (Scheme 16)
8. If you are not replacing the front bearing and/or rear bearing, go to «BRUSHES»(ref-162803-S24995563642004061000000). Remove the rotor from the rotor drive-end housing. (Scheme 17)
9. Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive end housing for seizure marks. If the rotor is damaged, replace the rotor assembly. If the rotor is OK, go to next step.
10. Remove the rear bearing using a puller. (Scheme 18)
11. With a hammer, driver and attachment, install a new rear bearing in the rotor shaft. (Scheme 19)
12. Remove the front bearing retainer plate. (Scheme 20)
13. Drive out the front bearing with a brass drift and hammer. (Scheme 21)
14. With a hammer, driver and attachment, Install a new front bearing in the drive end housing. (Scheme 22)

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22