Toyota 27060-62160-84
Alternator

Start the alternator service procedure with rear end cover removal by detaching both the nut and terminal insulator and afterward removing the 3 nuts together with the end cover. Unscrew the 2 screws enabling you to remove the brush holder followed by its cover removal. The voltage regulator requires removal of its three screws. The rectifier holder requires detachment when executing this step by first removing its 4 screws as well as the 4 rubber insulators. Special Service Tool 09820-63010 should be employed for pulley maintenance through engagement with a torque wrench for clockwise tightening to 39 Nm (400 kgf.cm, 29 ft.lbf) in order to secure the tool onto the rotor shaft. The adapter should be placed in a vise followed by generator installation and finally a counterclockwise turn of the pulley nut while ensuring the rotor shaft stays undamaged with a half turn maximum rotation. Tear the generator from the adapter after removing both the socket tool as well as the pulley holding tool before uninstalling the pulley nut followed by the pulley. The rectifier end frame comes off first by turning loose its 4 nuts and utilizing Special Service Tool 09286-46011 before extracting the generator washer with snap ring pliers. The rectifier end frame should be placed onto the pulley before installation of the drive end frame rotor and proper orientation of the generator washer for assembly. Use a 29 mm socket wrench along with a press to gently tighten the rectifier end frame while securing it with 4 nuts at a torque measure of 4.5 N.m (45 kgf.cm, 39 in.lbf) torque. First secure the pulley shaft with your hand before tightening the nut then secure the pulley holding tool with a torque wrench to reach a torque of 39 Nm (400 kgf.cm, 29 ft.lbf) in clockwise direction. The procedure begins by securing the adapter in a vise while inserting the generator before tightening the pulley nut to 110.5 N.m (1,128 kgf.cm, 81 ft.lbf). The generator needs to be later removed from both the adapter and the socket and pulley holding tool. Place 4 rubber insulators onto the lead wires before installing them into the rectifier with 4 screws fastened at 2.0 N.m (20 kgf.cm, 18 in.lbf) torque. Strengthen the installation of the brush holder and voltage regulator by placing the brush holder cover onto the brush holder before you install both parts positionally on the rear end frame with the brush holder cover must stay aligned during setup and drive five mounting screws until you create a 1 mm (0.04 in.) gap between the brush holder cover and connector. Secure the rear end cover with 3 nuts that need to be torque to 4.5 N.m (45 kgf.cm, 39 in.lbf) then attach the terminal insulator with a nut at 4.1 N.m (42 kgf.cm, 36 in.lbf) to achieve smooth rotor rotation.

Torque the pivot bolt to 51 N.m (520 kgf.cm, 38 ft.lbf) and the lock nut to 18.5 N.m (189 kgf.cm, 25 ft.lbf).

Disconnect the wire harness using the clip.

Tighten the pulley nut to 110.5 N.m (1,128 kgf.cm, 81 ft.lbf).

Next, remove the PS vane pump from the engine, followed by the engine under cover, and then the No.2 fan shroud by taking out the 2 clips.

Hand-tighten the pulley nut, then hold SST (A) with a torque wrench and tighten SST (B) to 39 N.m.

Turn SST (B) to detach SST (A and B), then remove the pulley nut and pulley.

Loosen the adjusting lock bolt and pivot bolt before loosening the adjusting bolt to remove the drive belt.

First, install the generator using the bolt and nut, ensuring a torque of 39 Nm (400 kg.cm, 29 ft.lb). Then connect the generator connector, followed by the generator wire with the nut and rubber, and install the cap.

Remove 4 screws and 4 rubber insulators to take out the rectifier holder.

Remove the pivot bolt and adjusting lock nut to take out the generator.