Honda CRV/Odyssey 1995-2000 Repair Information

Alternator

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TESTING Voltage Drop Test



These tests will show the amount of voltage drop across the alternator output wire from the alternator output (B+) terminal to the battery positive post. They will also show the amount of voltage drop from the ground (-) terminal on the alternator.

A voltmeter with a 0-18 volt DC scale should be used for these tests. By repositioning the voltmeter test leads, the point of high resistance (voltage drop) can easily be found. Test points on the alternator can be reached by either removing the air cleaner housing or below by raising the vehicle.

  1. Before starting the test, make sure the battery is in good condition and is fully charged. Check the conditions of the battery cables.
  2.  
  3. Start the engine, let it warm up to normal operating temperatures, then turn the engine OFF .
  4.  
  5. Connect an engine tachometer, following the manufacturer's directions.
  6.  
  7. Make sure the parking brake is fully engaged.
  8.  
  9. Start the engine, then place the blower on HIGH, and turn on the high beam headlamps and interior lamps.
  10.  
  11. Bring the engine speed up to 2,400 rpm and hold it there.
  12.  
  13. To test the ground (-) circuitry, perform the following:
    1. Touch the negative lead of the voltmeter directly to the positive battery terminal.
    2.  
    3. Touch the positive lead of the voltmeter to the B+ output terminal stud on the alternator (NOT the terminal mounting nut). The voltage should be no higher than 0.6 volts. If the voltage is higher than 0.6 volts, touch the test lead to the terminal mounting stud nut, and then to the wiring connector. If the voltage is now below 0.6 volts, look for dirty, loose or poor connections at this point. A voltage drop test may be performed at each ground (-) connection in the circuit to locate the excessive resistance.
    4.  

  14.  
  15. To test the positive (+) circuitry, perform the following:
    1. Touch the positive lead of the voltmeter directly to the negative battery terminal.
    2.  
    3. Touch the negative lead of the voltmeter to the ground terminal stud on the alternator case (NOT the terminal mounting nut). The voltage should be no higher than 0.3 volts. If the voltage is higher than 0.3 volts, touch the test lead to the terminal mounting stud nut, and then to the wiring connector. If the voltage is now below 0.3 volts, look for dirty, loose or poor connections at this point. A voltage drop test may be performed at each positive (+) connection in the circuit to locate the excessive resistance.
    4.  

  16.  
  17. This test can also be performed between the alternator case and the engine. If the test voltage is higher than 0.3 volts, check for corrosion at the alternator mounting points or loose alternator mounting.
  18.  

Output Voltage Test

  1. Before starting the test, make sure the battery is in good condition and is fully charged. Check the conditions of the battery cables.
  2.  
  3. Perform the voltage drop test to ensure clean and tight alternator/battery electrical connections.
  4.  
  5. Be sure the alternator drive belt is properly tensioned, as outlined in General Information and Maintenance .
  6.  
  7. A volt/amp tester such as the VAT-40 or an equivalent, which is equipped with a battery load control (carbon pile rheostat), full field tester and an inductive-type pickup clamp (ammeter probe) is used for this test. Make sure to follows all directions supplied with the tester.
  8.  
  9. Start the engine and let it run until it reaches normal operating temperature.
  10.  
  11. Connect the VAT-40 or equivalent and turn the selector switch to position 1 (starting). Make sure all electrical accessories and lights are turned OFF.
  12.  

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Typical charging system output voltage test connections

  1. Set the parking brake, place the transmission in Park or Neutral, and start the engine. Operate the throttle and hold the engine at 3,000 rpm with all accessories in the off position, until the radiator cooling fan comes on. Then allow the engine to idle for 15 seconds.
  2.  
  3. Raise the engine speed to 2,000 rpm and check the voltage. If the voltage is less than 15.1 volts, go to the next step. If the voltage is greater than 15.1 volts, replace the alternator.
  4.  
  5. Allow the engine to idle with all electrical accessories turned off. Turn the selector switch on the VAT-40 or equivalent to position 2 (charging).
  6.  

See Figures 2 and 3

Click image to see an enlarged view

Fig. Fig. 2: VAT-40 charging system tester. Similar testers are available that perform as well



Click image to see an enlarged view

Fig. Fig. 3: A rear view of the alternator showing the regulator, end cover and full field access hole locations

  1. Remove the inductive pick-up and zero the ammeter.
  2.  
  3. Place the inductive pick-up over the B terminal wire from the alternator, making sure the arrow points away from the alternator.
  4.  
  5. Raise the engine speed to 2,000 rpm and read the voltage. If the voltage is 13.5 volts or greater, go to the next step. If the voltage is below 13.5 volts, replace the alternator.
  6.  
  7. Apply a load with the VAT-40 or equivalent until the battery voltage drops to between 12-13.5 volts. If the amperage output is 75 amps or more, the charging system is good. If the amperage output is below 75 amps, go to the next step.
  8.  


WARNING
When performing the full field test, do not allow the voltage to exceed 18 volts as damage to the electrical system may occur.

  1. Perform a full field test by attaching the full field probe from the VAT-40 or equivalent into the full field terminal inside the full field access hole on the back of the alternator. Hold the engine speed to 2,000 rpm, switch the field selector to the A (Ground) position, and check the amperage reading.

    CRV models: If the amperage is 65 amps or more, replace the voltage regulator. If the amperage is less than 65 amps, replace the alternator.
     
    Odyssey models: If the amperage is 75 amps or more, replace the voltage regulator. If the amperage is less than 75 amps, replace the alternator.
     

  2.  

REMOVAL & INSTALLATION CRV



  1. Note the radio security code and the radio presets.
  2.  
  3. Disconnect the negative battery cable, then the positive.
  4.  
  5. Detach the four prong connector and the white wire from the rear of the alternator.
  6.  
  7. Remove the alternator adjusting bolt.
  8.  
  9. Remove the locknut.
  10.  
  11. Remove the alternator belt.
  12.  
  13. Remove the alternator assembly.
  14.  

See Figure 4

Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the alternator mounting- CRV shown

  1. Alternator installation is the reverse of the removal procedure.
  2.  
  3. Connect the positive battery cable, then the negative battery cable. Enter the radio security code and station presets.
  4.  


WARNING
Be sure to adjust the alternator belt to the proper tension or alternator bearing failure may occur.Odyssey Models

4-cylinder engines
  1. Note the radio security code and the radio presets.
  2.  
  3. Disconnect the negative battery cable, then the positive.
  4.  
  5. Remove the power steering pump as follows:
    1. Loosen and remove the pump adjusting bolt, mounting bolt and nuts.
    2.  
    3. Remove the power steering belt.
    4.  
    5. Cover the alternator with a suitable, absorbent shop towel.
    6.  
    7. Remove the two bolts that secure the power steering pump outlet line to the pump.
    8.  
    9. Carefully remove the pipe from the pump, and while removing place the O-ring from the fitting aside.
    10.  
    11. Wrap the end of the hose with a clean shop towel and place the hose aside. Cover the hole in the power steering pump with a small piece of cloth, and then cover the cloth with a piece of duct tape or electrical tape to hold the cloth in place.
    12.  
    13. Carefully remove the power steering pump taking care not to spill fluid from the covered hole, and place the pump aside onto a thick shop towel away from the alternator.
    14.  

  6.  
  7. Detach the four prong connector and the black wire from the rear of the alternator.
  8.  
  9. Remove the alternator adjusting bolt.
  10.  
  11. Remove the locknut.
  12.  
  13. Remove the alternator belt.
  14.  
  15. Remove the alternator assembly.
  16.  

See Figure 5

Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the alternator mounting-4-cylinder Odyssey shown

To install:
  1. Install the alternator in the reverse order of removal.
  2.  
  3. Check and properly tension the alternator belt as outlined in General Information and Maintenance .
  4.  
  5. Reinstall the power steering pump in the reverse order of removal, using a new O-ring for the power steering outlet hose fitting. If in an emergency, and the power steering hose O-ring must be re-used, coat the O-ring with a light film of power steering fluid before installing it.
  6.  


WARNING
Be sure to adjust the alternator belt and power steering belts to the proper tension or bearing failure may occur.

  1. Connect the positive battery cable, then the negative battery cable. Enter the radio security code and station presets.
  2.  
  3. Start the engine and turn the steering wheel full left, full right and the full left. Check the power steering fluid level and top off as necessary using only Honda Power Steering Fluid.
  4.  


WARNING
Substituting another power steering fluid could cause damage to the power steering components.

V6 ENGINE
  1. Note the radio security code and the radio presets.
  2.  
  3. Disconnect the negative battery cable, then the positive.
  4.  
  5. Move the auto tensioner to relieve tension on the serpentine drive belt and remove the belt.
  6.  

See Figure 6

Click image to see an enlarged view

Fig. Fig. 6: Move the auto tensioner (A) to relieve the tension from the alternator belt (B), then remove belt

  1. Detach the four prong connector and the black wire from the rear of the alternator.
  2.  
  3. Remove the alternator mounting bolt, the bracket mounting bolt and the harness clamp from the alternator.
  4.  

See Figure 7

Click image to see an enlarged view

Fig. Fig. 7: After the mounting bolts and clamp are removed, you can remove the alternator

  1. Remove the alternator assembly.
  2.  
  3. Alternator installation is the reverse of the removal procedure.
  4.  
  5. Connect the positive battery cable, then the negative battery cable. Enter the radio security code and station presets.
  6.  

 
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