Toyota 27060-22200-84
Alternator

A correct alternator service begins with rear end cover removal through sequential detachment of the nut and terminal insulator followed by bolt, three nuts, plate terminal, and end cover. Start by detaching the brush holder along with the voltage regulator through the removal of the brush holder cover followed by the 5 screws before removing the brush holder and voltage regulator and taking off the seal plate from the rectifier end frame. The repair of the rectifier holder starts by unscrewing its 4 screws along with removing the holder and extracting the 4 rubber insulators. The pulley removal process requires using Special Service Tool 09820-63010 which needs attachment to the rotor shaft using torque wrenches while tightening the socket clockwise until it reaches 39 Nm (400 kgf.cm, 29 ft.lbf) torque. Set the adapter onto a vise then put the socket inside while adding the pulley nut and use the tool to rotate counterclockwise but stop before a half turn to protect the rotor shaft. Uninstall the generator from the adapter by first removing the socket compound with the pulley holding tool then you can remove the pulley nut and pulley. To disconnect the rectifier end frame first remove all four nuts along with the wire clip before using tool O9286-46011 to remove the frame then eliminate the generator washer from the rotor. Installation begins with placing the rotor inside the drive end frame before adding the generator washer onto the rotor followed by pressing in the rectifier end frame with a 29 mm socket wrench until secured with the wire clip and four nuts and torqued Nut A to 4.5 Nm (46 kg.cm, 40 in.lb) and Nut B to 5.4 Nm (55 kg.cm, 48 in.lb). Secure the pulley to its shaft by using the pulley holding tool combined with a torque wrench. Maintain clockwise force until you reach 39 N.m (400 kg.cm, 29 ft.lb). While performing this operation make sure the tool remains on the pulley shaft. After installing the generator on the adapter users should torque the pulley nut to 111 N.m (1,132 kg.cm, 82 ft.lb). The rectifier holder requires installation with 4 rubber insulators in the proper direction before securing it with torques of 2.9 Nm (30 kg.cm, 26 in.lb) using 4 screws. First, the seal plate needs to be positioned on the rectifier end frame before adding the voltage regulator and brush holder in accordance with correct installation direction and securing with 5 screws at 2.0 Nm force (20 kg.cm torque, 18 in.lb). The installation process ends by mounting the rear end cover with its plate terminal installed through bolt and 3 nuts, then torquing Nut to 4.4 Nm (45 kg.cm, 39 in.lb) and Bolt to 3.9 Nm (39 kg.cm, 35 in.lb). Subsequently, attach the terminal insulator with correct nut torque at 4.1 Nm (42 kg.cm, 36 in.lb) while verifying the rotor's smooth rotation.

For the 2ZZ-GE, remove the 2 bolts and generator bracket, then take out the 2 bolts and generator.

Install the generator bracket with 2 bolts, torquing them to 29 Nm (295 kg.cm, 21 ft.lb).

Remove the brush holder cover, 5 screws, brush holder, and voltage regulator, then take off the seal plate from the rectifier end frame.

Turn the socket to detach the socket and pulley holding tool, then remove the pulley nut and pulley.