Toyota 27060-21020-84
Alternator

Begin generator assembly overhaul by using Special Service Tool 09820-63010 (or its alternatives 09820-06010 and 09820-06020) to remove the pulley by attaching the tool to the rotor shaft so it can reach a torque force of 39 Nm (400 kgf.cm, 29 ft.lbf). Tighten the pulley nut counterclockwise for less than half a turn until you detach the generator from the adapter before pulling out the pulley nut and pulley. The procedure begins by disconnecting the rear end cover through the removal sequence of nut and terminal insulator and then bolt and plate terminal and three nuts. Start the procedure by taking off the generator brush holder cover then unscrewing its two screws before removing the three screws holding the regulator in place. Special Service Tool 09286-46011 helps users remove the generator rectifier end frame by first unfastening the four screws holding the generator holder with rectifier then taking away its four rubber insulators, seal plate and four nuts, and clip code. You must first detach the generator washer before extracting the rotor out of the drive end frame accurately. Terminal F to B and F to E should show a specific level of continuity in the regulator assembly so you should replace the regulator in case this condition is not met. Open circuits and grounds of the generator rotor assembly should be checked while verifying the slip rings have correct continuity and ensuring the slip rings do not touch the rotor. Replace the rotor as needed. Use vernier calipers to measure the slip ring diameter which must stay within standard limits while checking the bearing condition for wear. Examine both the positive and negative rectifiers of the generator holder with rectifier for continuity until you need to replace the rectifier holder when the continuity is not as specified. The stator coil should be inspected for open circuits along with grounds while missing continuity points to the generator assembly for replacement and a bearing wear check must be performed. Rephrase the brush holder assembly replacement rule when the exposed brush length falls under the minimum acceptable standard. The installation of the generator rotor assembly requires putting the rotor along with the washer in their original positions. The 19 mm socket wrench allows users to press in the end frame of the generator rectifier before securing it with four nuts and clip code at specified torque values. Then users install seal plate and rubber insulators. Connect the generator holder with its rectifier parts by installing four screws at the appropriate torque levels and then connect generator regulator parts by installing three screws followed by the generator brush holder assembly connection with two screws while maintaining correct installation orientation. The final step includes attaching the rear end cover through bolt and three nut torque specifications before securing the terminal insulator with a nut and installing a generator pulley by hand. After this apply the pulley nut torque settings with a holding tool to 39 Nm (400 kgf.cm, 29 ft.lbf) then continue to 111 Nm (1,125 kgf.cm, 81 ft.lbf) to get smooth pulley movement.

The alternator removal process starts with separating the wire clamp from the wire clip on the rectifier end frame followed by unretooling the rubber cap and nut to disconnect the generator wire. The generator receives its connection from both the generator connector and harness clamp until completion. Begin the process by removing the drive belt after loosening its 2 securing bolts and unfasten the 2 bolts which secure the generator. To install the generator start by securing it into position and then tighten the 2 bolts in a temporary manner. You must install the drive belt followed by belt tension adjustment before securing the 2 bolts with this torque specification: 14 mm head 18 Nm (185 kg.cm, 14 ft.lb) and 17 mm head 54 Nm (550 kg.cm, 40 ft.lb). Begin by applying the generator connector then install the harness clamp followed by attaching the generator wire before completing with the nut and rubber cap. To finish the procedure rejoin the generator wire while installing the rubber cap followed by the nut.

Temporarily install the fan and generator V-ribbed belt on each pulley.

Take off the socket and pulley holding tool, followed by the pulley nut and pulley.

Remove the 4 screws and the holder, followed by the 4 rubber insulators.

Begin by disassembling it: remove the rear end cover by taking off the nut and terminal insulator, followed by the bolt, 3 nuts, plate terminal, and end cover.

Temporarily install the fan belt adjusting bar with bolt A and tighten the nut to a torque of 11 Nm (112 kgf.cm, 8 ft.lbf).