Alternator Overhaul: Reassembly

NOTE: Refer to the Exploded View if needed during this procedure.

Front Alternator Bearing
1. Install a new front bearing in the driver-end housing with a hammer, the driver handle, 15 x 135L, and the bearing driver attachment, 42 x 47 mm.
  
  Fig 1: Installing Front Bearing In Driver - End Housing Using Hammer
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
2. Install the front bearing retainer.
Fig 2: Front Bearing Retainer With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator Rotor
1. Install the drive-end housing.
  
  Fig 3: Identifying Alternator Rotor
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator Pulley
1. Install the pulley on the rotor and install the locknut, then torque the locknut to 110 N.m (11.2 kgf.m, 81 lbf.ft).
Fig 4: Installing Alternator Pulley On Rotor Using Wrench With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator Rear Housing Assembly
1. Install the rear housing assembly.
Fig 5: Alternator Rear Housing Assembly With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator Brush Holder
1. Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.6 mm (1/16 in) diameter) to hold them there.
  
  Fig 6: Inserting Pin Or Drill Bit In Alternator Brush Holder
  Courtesy of AMERICAN HONDA MOTOR CO., INC.
2. Install the brush holder, and pull out the pin.
Fig 7: Removing Pin Or Drill Bit From Alternator Brush Holder
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator End Cover
1. Install the end cover (A).
Fig 8: Alternator End Cover With Torque Specifications
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Alternator After Install - Check
1. After assembling the alternator, turn the pulley by hand to make sure the rotor turns smoothly and without noise.