Toyota 27060-0P241-84
Alternator

Start the alternator disassembly process by using a screwdriver to remove the generator pulley cap and then proceed with setting the Rotor Shaft Holding Tool (SST: 09820-63021) together with Clutch Pulley Wrench. Place the Rotor Shaft Holding Tool in a vise with its flat surface fixed before installing it. Fit the generator assembly tightly to the Clutch Pulley Wrench to get access to the clutch pulley. Then turn the wrench according to direction markup while inserting the rotor shaft end into the Shaft Holding Tool. Take apart the clutch pulley from the rotor shaft by using the SST generator assembly after its removal. Attach the generator assembly to the clutch pulley afterward you can remove the 3 nuts together with the generator rear end cover. Start by removing the terminal insulator of the generator coil and then proceed to take out the brush holder assembly by unscrewing its 2 screws. The removal of generator coil assembly requires removing 4 bolts while accessing the procedure through the SST (09950-40011, 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011). Take out the generator rotor assembly together with its washer at the end of the operation.

Assemble the generator by fastening it with two bolts that should be torques to 52 Nm (530 kgf-cm, 38 ft-lbf). You must install the wire harness clamp bracket by using a bolt with torque at 10 Nm (102 kgf-cm, 7 ft-lbf) followed by affixing the generator wire using a nut torqued to 9.8 Nm (100 kgf-cm, 87 in-lbf) then put on the terminal cap before coupling the generator connector. The wire harness clamp bracket requires a bolt installation with a torque setting of 10 Nm (102 kgf-cm, 7 ft-lbf) before attaching the wire harness clamp. The technician should first install the V-ribbed belt and then install the No. 1 engine cover sub-assembly followed by the cool air intake duct seal. Attach the cable to the negative battery terminal while keeping in mind that certain systems demand a system initiation process after reattachment.

You should dismantle the generator when performing repairs or servicing the alternator. The first step involves using a screwdriver to puncture the generator pulley cap at its center followed by prying the cap off while discarding it. Avoid putting the cap back into use. The vise supports the mounting of the generator while you install the Rotor Shaft Holding Tool (SST: 09820-63021) together with the Clutch Pulley Wrench on the pulley. The Clutch Pulley Wrench can be turned counterclockwise while a wrench holds the Rotor Shaft Holding Tool to loosen the generator pulley while the drive end frame remains secure in the vise and the Special Service Tool(A) maintains firm grip throughout the procedure. Uninstall the generator pulley after completing the loosening process. Start by placing the generator on its pulley before unbolted the 3 nuts then removing the cover and terminal insulator. The second step requires removing the generator brush holder assembly through screw removal of the 2 pieces. Detach the coil of the generator assembly by removing its four bolts followed by using SSTs named 09950-40011, 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, and 09957-04010. As the last step detach the generator rotor assembly together with the generator washer.

Disconnect the No. 2 oil cooler outlet tube sub-assembly, then remove the headlight assembly RH, radiator side deflector RH, and headlight bracket RH.

Attach the generator rear end cover to the generator coil with 3 nuts, torqued to 4.6 Nm (47 kgf-cm, 41 in-lbf).

Remove the V-bank cover sub-assembly, front wheel RH, No.1 engine under cover, front fender apron seal RH, and drain engine coolant.

Remove the cool air intake duct seal.