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HOMESERVICE MANUALSHONDA2002CIVIC SIREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 59 (CHARGING SYSTEM)ALTERNATOR OVERHAULOVERHAUL

2002 Honda Civic Si

Alternator Overhaul: Overhaul

2002 Honda Civic SiSECTION Overhaul

WARNING: This page is about a different car, the 2006 Acura MDX, 2005 Acura MDX, 2004 Acura MDX, and 2003 Acura MDX. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Refer to Figure as needed. .

Test the alternator and regulator before you remove them (see CHARGING SYSTEM INDICATOR CIRCUIT TROUBLESHOOTING ).
Remove the alternator (see ALTERNATOR REMOVAL AND INSTALLATION ).
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.

Fig 1: Removing Pulley Locknut With Wrench
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the three flange nuts.

Fig 2: Removing Flange Nuts
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the end cover (A) and the insulator (B). A.

Fig 3: Removing End Cover And Insulator
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the brush holder.

Fig 4: Removing Brush Holder
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the four bolts, then remove the rear housing assembly (A) and washer (B).

Fig 5: Removing Rear Housing Assembly And Washer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If you are not replacing the front bearing, go to step 13. Remove the rotor from the drive end housing.

Fig 6: Removing Rotor From Drive End Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 step 10.
Remove the front bearing retainer plate.

Fig 7: Removing Front Bearing Retainer Plate
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Drive out the front bearing with a brass drift and hammer.

Fig 8: Driving Out Front Bearing With Brass Drift And Hammer
Courtesy of AMERICAN HONDA MOTOR CO., INC.
With a hammer and special tools, install a new front bearing in the drive end housing.

Fig 9: Installing New Front Bearing In Drive End Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the length of both brushes (A) with vernier calipers (B).
- If either brush is shorter than the service limit, replace the brush holder assembly.
- If the brush length is OK, go to step 14.
  Alternator Brush Length
  - Standard (New): 10.5 mm (0.41 in.)
  - Service Limit: 1.5 mm (0.06 in.)
  Fig 10: Measuring Length Of Brushes With Vernier Calipers
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Rotor Slip Ring Test
Check for continuity between the slip rings (A).
- If there is continuity, go to step 15.
- If there is no continuity, replace the rotor assembly.
  
  Fig 11: Checking Continuity Between Slip Rings
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
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, and go to step 16.
- If there is continuity, replace the rotor assembly.
Assemble the alternator in the reverse order of disassembly, and note these items:
- Be careful not to get any grease or oil on the slip rings.
- If you removed the pulley, tighten its locknut to 110 N.m (11.2 kgf.m, 81.0 lbf.ft) when you reinstall it.