Toyota 27060-22040-84
Alternator

Altering the alternator requires starting with drive belt removal by first turning the drive belt tensioner clockwise until it loosens before removing the belt then installing the tensioner back in place. The service and repair of the alternator begins with disconnecting the wire clamp from the wire clip on the rectifier end frame and taking off the rubber cap and nut before disconnecting the generator wire followed by disconnecting the generator connector. The procedure for 2ZZ-GE alteration requires users to disassemble generator bracket by extracting 2 bolts followed by generator removal. Install the generator first by inserting two bolts while torquing the 14 mm head to 25 N.m (250 kgf.cm, 18 ft.lbf) on 1ZZ-FE and 2ZZ-GE to 54 N.m (550 kgf.cm, 40 ft.lbf) and 58 N.m (590 kgf.cm, 43 ft.lbf) torque values, respectively. The installation of the generator bracket with 2 bolts requires a torque setting of 29 N.m (295 kgf.cm, 21 ft.lbf) for the 2ZZ-GE. Next, connect the generator connector and generator wire while tightening the nut and applying the rubber cap before reinstallation. Finally, reinstall the drive belt.

You must start alternator servicing by working on the drive belt according to these steps: rotate the tensioner clockwise until the belt becomes loose enough to remove it and afterward place the tensioner correctly. The next step requires the removal of RH engine mounting insulator from the system. Begin removal of generators by first unfastening the wire clamp from its wire clip fixture on rectifier end frame components before unfastening the generator wire by removing the cap and nut. The last step includes disconnecting the generator connector. Remove the generator by taking out its two securing bolts. First for installation secure the generator to the two bolts with careful torque adjustments of 25 N.m (255 kgf.cm, 18 ft.lbf) for 12 mm heads while using 54 N.m (550 kgf.cm, 40 ft.lbf) for 14 mm head preservation. Reconnect the wire clamp to the wire clip first while you also connect the generator connector and generator wire before using the nut and cap for final wire security. Reinstall the RH engine mounting insulator followed by the drive belt installation process that must end with a clockwise turn of the drive belt tensioner to achieve proper security.

The generator servicing begins with dismantling it through the process of removing the rear end cover starting with the nut and terminal insulator and moving onward to the bolt and 3 nuts and plate terminal and end cover. The service begins with separating these two components by first stripping off the brush holder cover with its 5 screws and then disconnecting the brush holder and voltage regulator. Afterward detach the seal plate from the rectifier end frame. The first step for the rectifier holder requires removing four screws and then the holder followed by removing four rubber insulators next. The pulley removal process requires Special Service Tool 09820-63010 and a torque wrench for rotating the socket clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf) until the tool fastens to the rotor shaft. Then place the adapter under a vise and attach the socket before adding the pulley nut. To prevent rotor shaft damage twist the tool counterclockwise until you reach around half a turn of the pulley nut. Complete the adapter procedure by extracting the generator followed by removing the socket and pulley holding tool and then uninstalling the pulley nut and pulley. Remove the 4 nuts and wire clip of the rectifier end frame before using Special Service Tool 09286-46011 to detach the frame while also removing the generator washer on the rotor. The reassembly process starts by putting the rotor onto the drive end frame then adding the generator washer to the rotor followed by press-fitting the rectifier end frame using a 29 mm socket wrench while securing it with the wire clip and applying torques to the specified nuts: Nut A at 4.5 Nm (46 kg.cm, 40 in.lb) and Nut B at 5.4 Nm (55 kg.cm, 48 in.lb). The pulley installation requires manual nut securing followed by pulley holding tool application (Special Service Tool 09820-63010) to torque the shaft to 39 Nm (400 kg.cm, 29 ft.lb) and verify pulley shaft attachment. The generator should remain on the adapter after torquing the pulley nut to reach 111 Nm (1,132 kg.cm, 82 ft.lb). The install process of the rectifier holder begins by adding the 4 rubber insulators then confirming the proper direction before applying 4 screws tight at 2.9 Nm (30 kg.cm, 26 in.lb). Place the seal plate on the rectifier end frame then install the voltage regulator after the brush holder while securing all components with 5 screws tightened to 2.0 Nm (20 kg.cm, 18 in.lb). Lastly, cover the brush holder. Install the rear end cover first by tightening the end cover and plate terminal with a bolt and 3 nuts properly torqued at 4.4 Nm (45 kg.cm, 39 in.lb) for the nuts and 3.9 Nm (39 kg.cm, 35 in.lb) for the bolt. After that, install the terminal insulator with its nut at a torque of 4.1 Nm (42 kg.cm, 36 in.lb). Ensure the rotor rotates smoothly. The first step for bearing replacement involves the front bearing where you should remove four screws along with the bearing retainer and bearing before pressing out the bearing using Special Service Tools 09950-60010 (09951-00350) and 09950-70010 (09951-7100). Replace the bearing retainer by installing screws at 3.0 Nm (31 kg.cm, 27 in.lb) torque using tools 0995-60010 (09951-00530) and 0995-70010 (09951-07100). To replace the rear bearing first remove the bearing cover (outside) along with the bearing by using Special Service Tool 09820-00021 while maintaining fan integrity before removing the bearing cover (inside) to set on the rotor. Special Service Tool 09820-00030 enables installation of a new bearing before inserting the bearing cover (outside) using the Special Service Tool 09285-76010.

Install the generator wire with the nut, torqued to 9.8 N.m (100 kgf.cm, 87 in.lbf).

Torque the 12 mm head bolts to 25 Nm (250 kgf.cm, 18 ft.lbf).

Remove the generator holder with rectifier by unscrewing the four screws.

Disconnect the generator connector, the wire harness clamp, and the A/C connector.

Install the rear end cover and plate terminal with the bolt and 3 nuts, torquing Nut to 4.4 Nm (45 kg.cm, 39 in.lb) and Bolt to 3.9 Nm (39 kg.cm, 35 in.lb), then install the terminal insulator with the nut torqued to 4.1 Nm (42 kg.cm, 36 in.lb), and check that the rotor rotates smoothly.

Install the pulley by hand-tightening the nut, then use Special Service Tool 09820-63010 to torque it to 39 N.m (400 kg.cm, 29 ft.lb).

Install the wire harness clamp bracket with the bolt at 5.4 N.m.

Confirm the exposed brush length is between 9.5 - 11.5 mm and not less than 1.5 mm.

Install the rotor to the drive end frame, place the generator washer on the rotor, and press in the rectifier end frame using a 29 mm socket wrench, securing it with the wire clip and 4 nuts, torquing Nut A to 4.5 N.m and Nut B to 5.4 N.m.

Install the terminal cap No. 2.

Detach the brush holder cover, unscrew the 5 screws, remove the brush holder and voltage regulator, and take off the seal plate from the rectifier end frame.

First, remove the drive belt by turning the drive belt tensioner slowly clockwise to loosen it, then take off the drive belt and carefully reposition the drive belt tensioner.

Unscrew four nuts and a wire clip, then use Special Service Tool 09286-46011 to detach the frame and remove the generator washer from the rotor.

Hand-tighten the nut, then use Special Service Tool 09820-63010 to torque it to 39 N.m (400 kgf.cm, 29 ft.lbf).

Hold SST (A) with a torque wrench and tighten SST (B) clockwise to 39 N.m, ensuring SST (A) is secured to the rotor shaft. Then, mount SST (C) in a vise, insert SST (B) into SST (C), and attach the pulley nut to SST (C). Loosen the pulley nut by turning SST (A) without exceeding a half turn, then remove the generator from SST (C) along with the pulley nut and pulley.

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.

Connect the wire clamp to the wire clip on the rectifier end frame, then connect the generator connector and the generator wire, securing it with the nut and cap.