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Alternator failure after wash

 
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Old 03-15-2021, 11:03 AM
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Icon5 Alternator failure after wash

Hey all

So I decided to hose down my engine bay. I covered a few things with a plastic bag, including the fuse box, but I didn't cover the alternator because I wasn't planning on starting the engine for a couple of days after by which time the water that got inside the alternator should have evaporated. Regrettably, the alternator has failed.

After starting the car, the battery warning light came on. Also, the alternator was making a squealing noise. See the video here to hear the sound at 1500 RPM, 1100 RPM and 800 RPM (barely makes any sound at 800 RPM).

https://streamable.com/10vaap

My battery went flat in just over an hour.

I have checked both the ACG(S) fuse (37) and alternator/fuel pump fuse (12). Both are are fine. I also disconnected the alternator power cable and let it sit overnight to allow any water that may have gotten inside to evaporate. This didn't help.

The fact that the alternator is now making a squealing noise makes me think the problem is mechanical rather than electrical but perhaps its both.

What do others think?

Last edited by Kolusion; 03-15-2021 at 02:08 PM.
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Old 03-19-2021, 02:36 PM
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Re: Alternator failure after wash

Could be mechanical...alternators are mechanical devices. Could be a bearing, or the pulley, but in any case, since all indicators point to the alternator, pull it off and take it to the nearest auto parts store for testing. Rebuilt alternators are cheap, and it's easy to replace.
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Old 03-24-2021, 11:34 AM
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Re: Alternator failure after wash

Quote:
Originally Posted by Jamie View Post
Could be mechanical...alternators are mechanical devices. Could be a bearing, or the pulley, but in any case, since all indicators point to the alternator, pull it off and take it to the nearest auto parts store for testing. Rebuilt alternators are cheap, and it's easy to replace.
I have narrowed the squealing sound down to the rear bearing.


So I cleaned out the alternator connector and the port that it plugs into with two passes of WD-40. These things were filthy! Check it out...

https://ibb.co/NFF5XRp

https://ibb.co/x24Jfsd


This is the result of the port after the WD-40...

https://ibb.co/FgLGcZx


Cleaning the connector and port didn't resolve the issue, so now I am pulling apart the alternator to degrease everything with WD-40 and repack the two bearings with bearing grease.

I have hit a problem dissembling the alternator because Denso wanted to be impractical and seal the case with a ****ty design. I am hoping someone can help me with it.

There are four nuts and four of something else with threads that hold the case together. I have removed the nuts but I don't know how to remove the thread things. Check out the photo's to see what I mean...

https://ibb.co/NpKfZqh

Does anyone know how these thread things can be removed?


So far, this is what I have removed...

https://ibb.co/9TC69Fn


This is the brushes and slip rings. I don't think they are the problem but if anyone can see something that isn't right then please let me know...

https://ibb.co/LZDgQk8

https://ibb.co/JCGwD4f

Last edited by Kolusion; 03-24-2021 at 11:40 AM.
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Old 03-27-2021, 12:39 PM
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Re: Alternator failure after wash

So I got the nut off and proceeded to separate the alternator housing but can't I do it. Here's a video of me explaining the problem while demonstrating it...

https://streamable.com/8zxp3c
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Old 03-28-2021, 08:36 AM
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Re: Alternator failure after wash

So, as I suspected, Honda ****ed up the shop manual and the pulley actually does need to come off when replacing the rear bearing. As I damaged the alternator while banging it with a hammer and it's become too much of a hassle to get the parts for a repair, and that I am getting rid of the car in 11000 kilometres, I am just going to get a second hand alternator or an OEM unit to keep me going, what ever's cheaper.
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Old 04-08-2021, 01:43 PM
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Re: Alternator failure after wash

// Face palm // I knew I should have gotten a multimeter to test the alternator when this problem started but I didn't get one due to circumstances outside of my control.

So I fully charged my battery and installed the new alternator and the battery light was no longer coming on. Great I thought, but the belt was squealing a lot, so I started trying to find the cause. After about 30 minutes with the engine running, my battery light turned on again, and it turned on as soon as the fan came on. Perhaps the battery light didn't come on at the start because it was fully charged but then came on when it started to run down.

So I then had a closer look at everything. Knowing it can't be the alternator, I followed the alternator belt and noticed that the crankshaft pulley was wobbling, and when it wobbles it looks like it has split apart. That abnormal pulsing sound is still present and I am wondering if it has something to do with the crankshaft pulley.

The alternator belt is spinning the alternator pulley so the alternator must be charging?! But I don't know. I temporarily tightened the belt even more but it didn't make a difference.

The problem was not happening before this abnormal pulsing sound so what ever is causing this sound probably has something to do with it.

I followed the cable from the alternator to the fusebox. It looks all good. I cleaned the alternator wire connector again with WD-40 and scraped the terminals with a metal paper clip, and even sprayed WD-40 on the alternator wire connection in the fusebox, but nothing has helped. I am starting to lose patience with this car, it is wasting my life and I have started having visions again of a tow truck coming to pick it up and taking it to the wreckers!

If anyone thinks the problem may be something else then please let me know!

Also, does anyone know where in the shop manual I can find the procedure for replacing the crankshaft pulley? I have looked but can't find it.

I have taken some more videos of the problem...

Wobbly crankshaft pulley...

https://streamable.com/4okumi


Pulsing sound (really noticeable at 34 seconds), and the battery light comes on with fan...

https://streamable.com/9ik6bi

Last edited by Kolusion; 04-09-2021 at 04:08 PM.
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