Honda_Odyssey_2001-2006

Alternator

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Alternator wiring harness connectors
     
    Alternator mounting bolts
     
    Wiring harness clamp
     
    Alternator

    Click image to see an enlarged view

    Fig. Alternator mounting-J35A1 and J35A4 engines



    Click image to see an enlarged view

    Fig. Alternator mounting-J35A6 and J35A7 engines

     

  4.  

To install:

  1. Install or connect the following:

    Alternator
     
    Wiring harness clamp. Tighten the bolt to 105 inch lbs. (12 Nm).
     
    Alternator mounting bolts. Tighten the 10mm bolt to 33 ft. lbs. (44 Nm) and the 8mm bolt to 16 ft. lbs. (22 Nm).
     
    Alternator wiring harness connectors. Tighten the battery terminal nut to 105 inch lbs. (12 Nm).
     
    Accessory drive belt
     
    Negative battery cable
     

  2.  

Testing



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 Section 1.
  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.

    Click image to see an enlarged view

    Fig. Typical charging system output voltage test connections

  12.  
  13. 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.
  14.  
  15. 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.
  16.  
  17. 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).

    Click image to see an enlarged view

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



    Click image to see an enlarged view

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

  18.  
  19. Remove the inductive pick-up and zero the ammeter.
  20.  
  21. Place the inductive pick-up over the B terminal wire from the alternator, making sure the arrow points away from the alternator.
  22.  
  23. 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.
  24.  
  25. 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.
    WARNING
    When performing the full field test, do not allow the voltage to exceed 18 volts as damage to the electrical system may occur.

  26.  
  27. 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.

    If the amperage is 75 amps or more, replace the voltage regulator. If the amperage is less than 75 amps, replace the alternator.
     

  28.  

Voltage Drop Test

NOTE
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.  

 
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