[0dyfamily]

Was working fine intermittently few days back. Now it is not working :-(.

There is no ground from the casing. I think this could be the issue. Where does the regulator get the ground from (casing?)? Does the casing get the ground from the alternator bracket? The alternator bracket is totally rusted. Should I replace it? Could this be the issue?

Virtually every alternator built for automotive applications grounds via the case. The bracket serves as a ground path, but ultimately its prime duty is to correctly position the alternator.

I don't have the torque values for a 2005 Odyssey, but you need to make sure these are torqued properly or the bracket can loosen, break bolts ... the results aren't good. Whether you replace the bracket or not, it needs to be correctly torqued on all fasteners.

... I had to struggle a bit to press the alternator's bottom half into the slot ("U-bracket") with the holes aligned. Had to use a pry bar to align the holes. May be if you install the top bracket first it will easier to pivot the bottom part.

The alternator has a burly roll pin in one side that fits into the "U-bracket." If you compress the side that sticks out towards the U-bracket with a big C-clamp and socket, it makes fitting the alternator easier.

That contact with the "U-bracket" is your largest ground path. I typically clean those well, shine up with emery paper, coat with dielectric grease, and install. I shine up the big bolt's flange and coat the flange with dielectric grease, too.

OF

 

[jdm06ody]

Was working fine intermittently few days back. Now it is not working :-(.

There is no ground from the casing. I think this could be the issue. Where does the regulator get the ground from (casing?)? Does the casing get the ground from the alternator bracket? The alternator bracket is totally rusted. Should I replace it? Could this be the issue? I am assuming the bracket plays the role of positioning the alternator. So, can the bracket be replaced without removing the drive belt?

I tried to remove the bolt that connects a wire harness bracket to the alternator bracket. It sheared off :-(. See attachment. Red arrow points to the hole where the harness bracket is bolted. What's the part number of this bolt?

Thanks in advance!

FROM the alternator pin T102 black wire make sure they have continuity to chassis ground that's all you need to verify they have ground contact
see diagram below

 

[nirvana_1959]

 

[nirvana_1959]

FROM the alternator pin T102 black wire make sure they have continuity to chassis ground that's all you need to verify they have ground contact
see diagram below

T103 (from the alternator +B) is connected to T102. This is the charging cable that goes to +ve terminal of the battery. T102 and T103 should read ~12.5V when engine is not running and ~13.5V when the engine is running. In my case the reading goes down when the engine is running (which is to be expected with the load and the alternator is not "working"). My understanding is this could be due to poor grounding of the alternator or the alternator is toast. Since this an old vehicle I am going ahead and replacing the alternator itself.

 

[thscott]

T103 (from the alternator +B) is connected to T102. This is the charging cable that goes to +ve terminal of the battery. T102 and T103 should read ~12.5V when engine is not running and ~13.5V when the engine is running. In my case the reading goes down when the engine is running (which is to be expected with the load and the alternator is not "working"). My understanding is this could be due to poor grounding of the alternator or the alternator is toast. Since this an old vehicle I am going ahead and replacing the alternator itself.

Make sure your new alternator is a Denso brand.

 

[nirvana_1959]

Make sure your new alternator is a Denso brand.

OEM one is in backorder in Toronto. So, getting the reman Denso from Rock Auto (the VCM version).