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Generators & Regulators: Overhaul

NOTE: Use exploded view of generator for overhaul. See Fig 1.
Fig 1: Exploded View Of Denso Generator (3.2CL & 3.2TL)
G00012261Courtesy of AMERICAN HONDA MOTOR CO., INC.
  1. Test the alternator and regulator before you remove them. See CHARGING SYSTEM INDICATOR TEST  under TROUBLE SHOOTING.
  2. Remove the alternator. See ALTERNATOR  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. See Fig 2.
  4. Remove the three flange nuts "A" and the screw "B" from the alternator, then remove the plate terminal "C". See Fig 3.
  5. Remove the washer nut "A" and insulator "B" from the "B" terminal. Remove the end cover "C" and dust seal "D". See Fig 4.
  6. Remove the brush holder. See Fig 5.
  7. Remove the voltage regulator. See Fig 6.
  8. Remove the 4 screws "A". Remove the rectifier "B" and rubber seal "C". See Fig 7.
  9. Remove the 4 flange nuts. See Fig 8.
  10. Remove the 4 insulators "A" rear housing "B" and washer "C". See Fig 9.
  11. If you are not replacing the front bearing and/or rear bearing, go to RECTIFIER TEST . Remove the rotor from the stator drive-end housing. See Fig 10.
  12. 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.
  13. Remove the rear bearing using a puller. See Fig 11.
  14. With a hammer, driver and attachment, install a new rear bearing in the rotor shaft. See Fig 12.
  15. Remove the front bearing retainer plate. See Fig 13
  16. Support the stator housing in a vise, and drive out the front bearing with a brass drift "A" and hammer.
  17. Install a new front bearing in the stator housing. See Fig 14.
Fig 2: Removing Drive-End Housing Pulley Locknut
G00301969Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 3: Removing Stator Drive-End Housing Components
G00301971Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 4: Removing End Cover And Dust Seal
G00301970Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 5: Removing Brush Holder
G00301972Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 6: Removing Voltage Regulator
G00301973Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 7: Removing Rectifier And Rubber Seal
G00301974Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 8: Removing Flange Nuts
G00301975Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 9: Removing Rear Housing, Washer And Insulators
G00301976Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 10: Removing Rotor From Stator Drive-End Housing
G00301951Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 11: Removing Rear Bearing
G00298046Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 12: Installing Rear Bearing
G00301953Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 13: Removing Front Bearing Retainer Plate
G00301954Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig 14: Installing/Removing Front Bearing In Stator Housing
G00301977Courtesy of AMERICAN HONDA MOTOR CO., INC.
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