2003 HONDA CIVIC Workshop Manual

Charging System
Alternator Overhaul
Exploded View
BEARING
PULLEYLOCKNUT
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TERMINALINSULATOR
REAR HOUSINGASSEMBLY
INSULATORBUSHING
PULLEY
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REAR BEARING / ,/ ./ FRoNr B
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BRUSH \11BRUSH HOLOER HOLDER -\
TNSULATOR \l VOLTAGE }
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REGULATOR (-
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ROTOR
4-30

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Special Tools Required. Driver 07749-0010000. Attachment,52 x 55 mm 07746-0010400
NOTE: Refer to the Exploded View as needed during
this procedure.
1, Test the alternator and regulator before you
remove them (see page 4-22l,.
2. Remove the alternator (see page 4-29).
3. lf the front bearing needs replacing, remove thepulley locknut with a 10 mm wrench (A) and a
22 mm wrench (B). lf necessary, use an impact
wrencn.
Remove the harness bracket (A), insulator (B). three
flange nuts (C), and the screw (D), then remove theplate terminal (E).
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5. Remove the end cover (A) anddustseal {B).
Remove the brush holder (A), voltage regulator (B),
and the rubber seal {C}.
6.
L1i.21---^
tqLJ
B-"--|.
(cont'd)
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4-31

Charging System
Alternator Overhaul (cont'dl
7. Remove the four screws, then remove the rectifier
(A) and four insulators (B).
Remove the four flange nuts, then remove the rear
housing (A) and washer (B).
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4-32
f.r,e
9. lf you are not replacing the front bearing and/or
rear bearing, go to step '16. Remove the rotor from
the stator drive end housing.
Inspect the rotor shaft for scoring, and inspect the
bearing journal surface in the stator housing for
setzure marks.
. lf eitherthe rotororstatorhousing isdamaged,
replace the alternator,. lf both the rotor and the stator housing are OK,
go to step 11.
'l 1. Remove the rear bearing using a puller as shown.
10.
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12. With a hammer and commercially available tools
shown, install a new rear bearing on the rotor shaft.
NOTE: Installthe bearing using the inner race.
13. Remove the front bearing retainer plate.
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14. Supportthe stator housing in a vise, and drive out
the front bearing with a brass drift and hammer.
15. With a hammer and the specialtools, install a new
front bearing in the stator housing.
07749-0010000
07746-0010400
(cont'd )
4-33

Charging System
Alternator Overhaul (cont'd)
Rectitier Test
16. 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 eight diodes (four pairs). you
musttest each diode in both directions for
continuity with an ohmmeter that has diode
checking capability: a total of 16 checks.
. lf any diode is faulty. replace the rectifier
assembly. {Diodes are not available separately.)' lf all the diodes are OK, go to step 17.
/--:',t- -L . --- -o \-- l'-=
BP"
P,
P.
P,
P.
4-34
19.
'a
Alternator Brush Inspection
17. Measure the length of both brushes (A)with a
vernier caliper {B).
. lf either brush isshorterthanthe service limit,
replace the brush assembly.. lf brush length is OK, go to step '18.
Alternator Brush Length:
Standard (New): 10.5 mm (0.41 in.)
Service Limit: 1.5 mm (0.06 in.)
Rotor Slip Bing Test
18. Check that there is continuity between the slip rings
{A).
. lf there is continuity, go to step 19.. lf there is no continuity, replacethe alternator.
Check that there is no continuity between each slip
ring and the rotor (B) and the rotor shaft (C).
. lf there is no continuity, goto step 20.. lf there is continuity, replace the alternator.
\"

Stator Test
20. Checkthatthere is continuity between each pair of
leads (A).
lf there is continuity, go to step 21 .
lf there is no continuity, replace the alternator.
Check for no continuity between each lead and the
coil core (B).
. lf there is no continuity, goto step 22.. lfthere is continuity, replace the alternator.
Assemble the alternator in reverse order of
disassembly, and note these items:
. Be careful not to get any grease or oil on lhe slip
n ngs.. lf you removed lhe pulley, tighten its locknutto
111 N.m (11.3 kgf m,81.7 lbf.ft)whenyou install
it.
21.
22.
'--l-- --i
4-35

Gruise Control
Component Location Index
CLUTCH PEDAL POSITIONswtTcHTest, page 4-45Clutch Pedal Adjustment,page 12-4
t.- _,- _
CRUISE CONTROLACTUATORTest, page 4'43Replacement, page 4-44
CRUISE CONTROL UNITlnput Test, page 4-40
BRAKE PEDAL POSITION SWITCHTest, page 22-84Pedal Height Adjustment, page '19-6
CRUISE CONTROL INDICATOR(Built into gaug6 assembly)
ACTUATOR CABLEAdjustment, page 4-45
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4-36
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Circuit Diagram
' No.aloAl USAnod.lNo.20 itoAl C.md! modrlUISEF NOOD fUS'/iILAY IOX
-to ots BU/YIL
lcl H0Tii0llilllmdSTARTlllll
1 Honilsffroi
CTuICII PEDALP0sm0 swtrct
26 1113cnu6E coNTnoL uNtT l0
4-37