Honda 31150-P54-003 Regulator Assembly

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Do not attempt to overhaul the alternator; if replacing the brushes and regulator does not resolve the issue, take it to a dealer service department or repair shop for rebuilding or exchange. Begin by removing the alternator and placing it on a clean workbench. For Nippondenso alternators, remove the three rear cover nuts, the nut and terminal insulator, and detach the rear cover. Next, take out the two brush holder retaining screws and remove the brush holder from the rear end frame. Measure the exposed length of the brushes and compare it to the specified minimum; if it is less than required, replace the brush. Ensure each brush moves smoothly in the holder, then install the brush holder by depressing the brush with a small screwdriver. Secure the brush holder screws into the rear frame, reinstall the rear cover, and tighten the three nuts. Attach the terminal insulator and tighten it with the nut before reinstalling the alternator. For Mitsubishi alternators, remove the alternator from the vehicle and take out the through bolts from the alternator body. Mount the front of the alternator face down in a vice, using rags as a cushion, and remove all nuts from the back. Insert two standard screwdrivers into the two halves of the alternator to pry the rear case off, then separate the rotor from the alternator body, followed by the stator, regulator/brush assembly, and rectifier. Unsolder the regulator/brush holder assembly, applying heat carefully, and measure the length of the brushes; if worn past the limit, replace them by unsoldering the pigtails. When installing new brushes, ensure the pigtails are soldered so the brush limit line is about 0.079 to 0.118 inches above the end of the holder. To reassemble, compress the brushes into their holder and retain them with a straight piece of wire that can be pulled from the back when reassembled, completing the installation in reverse order of removal.