1 page HONDA CIVIC 1996 6.G Workshop Manual

Charging System
Troubleshooting (cont'd)
Alt6rnator/Regulator Test
NOTE: Make sure the baftery is sufficiently charged (see page 23-9j).
FIELDSELECTOR
LOAD AOJUSTER{CARAON PILEI
FULL FIELOTESTERLEAD IBLUI
VOLTMETERNEGATIVELEAD IBLKI
VOLTMETERPOStTtVELEAD (REDI
NEGATIVE TESTERCABLE IBLKI
POSITIVE TESTERCABLE IREDI
TEST SELECTORswrTcH
INDUCTIVEPICK-UP
IGRNI
INDUCNVEPICK.UP
TIVETEBMINAL
Alte.nator/Regulator Test'1 :L Connect a Sun VAT 40 (orequivalent tester), and tu rnthe selector sw;tch to position1(staning).2. Shift to neutral (A/T in E orE) position, and start theengine. Hold the engine at3,000 rpm with no load untilthe radiator fan comes on,then let it idle.3. Raise the engine speed to2,000 rpm, and hold it there.
ls the voltage over 15.1 V?
Alternalor/Regulator Te3t-2:1. Release the accelerator pedal,and let the engine idle.2. Make sure all accessories areturned ofi. Turn the selectorswitch to position 2 (charging).3. Bemove the inductive pick-up,and zero the ammeter,4. Place the inductive pick-upover the battery ground cableso that the arrow points to thebattery negatlve terminal.5. Raise the engine speed to2,000 rpm, and hold it there.
ls the voltage less than 13.5 V?
Alternator/Regulator Test-3:Apply a load with a VAT-40 untilthe battery voltage drops tobetween 12 - 13.5 V.
tffil rCI
[ @lBt* . ,*n 'aHrl
L-;-;l rs-
23-11A
To next page

The charging system is OK.ls the amperage 50 A or more?
Alternator/Regulator Test-4:
With the engine sPeed still at
2,000 rpm, fulltieid the alternator.
J
From previous page
CAUTION: The voltage will rise quickly when the allGrnator is flll-fielded Do not ellow
the vollage to exceed 18 V; il may damage the electrical syslem
NOTE: Attach a probe to a VAT 40 full field test lead, and insert the probe into the full field
access hole at the back of the alternator' Switch the field selector to the "A (GroLrnd)" posi
tion momentarilV, and check the amperage readlng
23-119

Charging System
Alternator Replacement
NOTE: Remove the alternator from below the vehicle.
'1. Make sure you have the anti-theft code for theradio, then write down the frequencies for theradio's preset buttons ('99 - 00 models).
2. Remove the battery negative cable, then disconnectthe positive cable.
3. Disconnect the 4P (or 3P) connector from the alter-naIor.
TERMINAL NUT7.85 N.m (0.8 kgf.m, 5.79lbf.ftl
{ }: Cansd.
4. Remove the terminal
the B terminal.
nut and the WHT wire from
23-120
5. Remove the adjusting bolt and through bolt nut,then remove the alternator belt from the Dullev.
UPPER MOUNTBRACKET BOLT44 N.m 14.5 kgt.m, 33 lbl.ftlALTERNATORAD.'USTING BOLT24 N.rh l2.a kgf.m, 17 lbtft)
ALTERNATORBOLT
a4 N.m 14.5 kstm.33lbf'ftl
LOWER MOUNTBRACKET BOLTSa4 N.m l{.5 kgf.m,33lbfft)
Pull out the alternator through bolt, then removethe alternator.
lf necessary, remove the mount bracket bolts. andthe upper and lower mount brackets
Adjust the alternator belt tension after installation(see page 23-125).
Enter the anti-theft code for the radio, then enter thecustomer's radio station presets ('99 - 00 models).
7.

JRotor Slip Ring Test
1. Check the resistance betlveen the slip rings
There should be 1 8 - 3 0 ohms
. lf resistance meets the specification, go to step 2.
. lf resistance does not meet the specification,
reolace the alternator'
SLIP BINGS
2. Check that there is no continuity between the slip
rings and the rotor or rotor shaft.
3. lf the rotor fails either continuity check, replace the
alternator.
Stator Test
'1. Check that there is continuity between each pair of
leads.
CORE
Check that there is no continuity between each lead
and the coil core.
lf the coil fails either continuity check, replace the
alternator.
ROTOR SHAFT
LEADS
1.
Alternator Brush InsPection
Separate the drive-end housing from the rear hous-
ing as described on page 23-121
Separate the rear housing from the stator/rectifier
assembly by removing the four screws and the ter-
minal nutfrom the rear housing {see page 23-121}
lvleasure the length of the brushes with vernrer
calrpers.
Alternator Brush Length:
O Standard {NEW} @ Service Limit
19.0 mm (0.75 in) 1 5.0 mm (0 20 in)
lf the brushes are less than the service limit, replace
them.
23-123

Gharging System
Rear Bearing Replacement
1. Pull offthe rear bearing,
. Make sure the tips of the bearing puller jaws arethin enough to fit between the bearing and theslip rings.
. Do not reuse the bearing.
SLIP RINGSBEARING PULLER
Use a hand press to install the new bearing. Applypressure only on the inner race to avoid damaging
the bearino.
REAB BEARING
23-124
Alternator Reassembly
1. Push the brushes in, then insert a pin or drill bit(about 1.8 mm diameter) to hold them there.
Heat the rear bearing seat in the rear housing asdescribed on page 23-121. After heating, continueimmediately with assembling before the rear bear-ing seat cools completely,
Put the rear housing/stator assembly and drive-endhousing/rotor assembly together. tighten the fourthrough bolts and pull out the pin.
REARSTATOR ASSEMBLY
After assembling the alternator, turn the pulley byhand to make sure the rotor rotates smoothlv andwithout noise.
BRUSHES
THROUGH BOLT
Iq
%*z
BRUSH AOCESS HOI."E

Fan Controls
Component Location Index
UNDER.HOOO
CONDENSER FAN RELAYTest, page 23-87
RADIATOR FAN RELAYTest, page 23 87
CONDENSERFAN MOTOR
TOR FAN MOTORRemoval, section 10
ENGINE COOLANTTEMPERATURE (ECTI
swtTcHRemoval, section 10Test, section l0
t lt lt lt tt l
tlTtlnr-l
mU!L-Jfl_l'1 - f-t t-_l -
I L--J L__J LJ f-----"1
o
^o
o"l
23-126

Gauge Assembly
Component Location Index
SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS
section (24) before performing repairs or service.
6x1.0mm9.8 N.m 11.0 kgf.m,22lbt.lrl
VEHICLE SPEED SENSOR {VSS)Troubleshooting, page 23-1 40
GAUGE ASSEMBLYGau ge/lndicator/TerminalLocation Index, page 23-129Removal, page 23-135Bulb Location, page 23-136Disassembly, page 23 138
PARKING BRAKE SWITCH
FLUIO LEVEL SW]TCH
23-128
ENGINE OIL PR€SSURE SWITCH

JGau ge/lndicator/Terminal
With tachometer;
CONNECTOR "A"
{A/T GEAR POSITION INDICATOR}
Location lndex
CONNECTOR "8"
{GAUGE and INOICATOR)CONNECTOB "C"
CONNECTOR "D"
{ABS INDICATORI
SPEEDOMETER:Indicates 60 km/h at 637 rpm or
60 mph at 1,025 rpm o{thevehicle speed sensor (VSS).
A/T GEAR POSITIONINDICATORSee page 23 149
TACHOMETER:Indicates 100 rpm at200 pulses per minuteol the ignition controlmodule (lCMi.FUEL GAUGEENGINE COOLANT TEMPERATURE (ECT) GAUGE
(cont'd)
23-129
(GAUGE end INDICATORI
A1-----------+816
JlltlllulllllrL
c1 --------->c13
1ililil{ilrL
oooo o 0006^
)og @ @ o^o @ )'l |. o
Fl- - -> F5E1_ _ -->E5D1- --+05
oo/ \oo
Gauge/Sending Unit Test, page 23-142

Gauge Assembly
Gauge/lndicator/Terminal Location Index (cont'd)
Without tachometer:
CONNECTOR "A"
IA/T GEAR POSITION INDICATORICONNECTOR "8"
{GAUGE and INDICATOR}CONNECTOR "C"
(GAUGE and INDICAIORI
CONNECTOR "F"
{SRS INDICATOR)CONNECTOR "D"
{ABS INDICATORI
SPEEDOMETER:Indicates 60 km/h at 637 rpm or60 mph at 1,025 rpm ofthevehicle speed sensor (VSS).
ENGINE COOLANT TEMPERATUFE (ECT) GAUGEA/T GEAR POSITIONINDICATOFSee page 23 149FUEL
A1 ------> 46
----> al4
B1. - --------------->B16
JilililHililil1
C1-- - --------..+C13
JililHililL
Oo_o-o O 0006
lus 0 0 Bu-. )
oo/ \oo
23-130
Gauge/Sending Unit Test, page 23 142

Gauge Assembly
(Wnh lachomolgr)
I cNfldt--]I CONTRoL II MODULE
I 0cM) :
tvl
i.ll
|
-i;,
i
TURN SIGNAUHAZAROWARNINGswtTcH
Circuit Diagram {cont'd)
Fh"lurous @)- BLrcwHT + BLKryEL
fi'Sfvrous 16r.- veLPAGE
RIGHT
V
IGR&ryE
LEFT
V
I
No.s (104)FUSE
V
IBEO/GRN
lru
8LU4RE0
ABSCONTROLUNIT
-rl
eLui'rvrr
G401G402G401G442
23-132