OEM 2001 Toyota Avalon Alternator

2001 Toyota Avalon Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2001 Toyota Avalon?

  A: The alteration servicing process begins with rear end cover removal by unfastening the nut and terminal insulator before proceeding to separate the screw and 3 nuts along with plate terminal and end cover. The brush holder and voltage regulator can be detached after removing the brush holder cover and 5 screws. Remove the rectifier holder through the process of unscrewing four screws followed by four rubber insulators and seal plate removal. Use Special Service Tool 09820-63010 to attach the pulley holding tool onto the rotor shaft before torquing the socket to 39 Nm (400 kgf.cm, 29 ft.lbf) clockwise. Place the adapter in a clamp while putting the socket inside before securing the pulley nut counterclockwise without rotating it more than halfway to protect the rotor shaft. After removing the adapter from the generator users should take out the socket tool and pulley holding device before removing the pulley and pulley nut. For rectifier end frame removal begin by detaching the wire clamps then unscrewing all 4 nuts and loosening the cord clips before using Special Service Tool O9286-46011 to detach the frame and extracting the drive end frame rotor and thrust washer. Reassembly starts with setting the rotor into the drive end frame followed by positioning the rectifier end frame on the pulley then setting the rotor. Take the thrust washer and place it on the rotor before pressing the rectifier end frame into position with a 29 mm socket wrench. Secure it using cord clip, 4 nuts that are torqued to 4.5 N.m (46 kgf.cm, 40 in.lbf) for Nut A and 5.4 N.m (55 kgf.cm, 48 in.lbf) for Nut B and then lock it in with the wire clamp. First tighten the pulley nut manually then apply the pulley holding tool to torque the nut to 39 N.m (400 kg.cm, 29 ft.lb) before achieving 111 N.m (1,132 kg.cm, 82 ft.lb). Later install the 4 rubber insulators onto the rectifier end frame before tightening 4 screws with 2.9 N.m (30 kgf.cm, 26 in.lbf) torque. Place the rectifier end frame voltage regulator and brush holder in proper orientation before fastening 5 screws to 2.0 N.m (20 kgf.cm, 18 in.lbf) torque while installing the brush holder cover. The installation process requires attaching the rear end cover with its end cover and plate terminal using 3 nuts and a screw which should be torqued to 3.9 N.m (35 in.lbf and 4.4 N.m (39 in.lbf specifications) respectively. Also torque the terminal insulator nut to 4.1 N.m (36 in.lbf). Ensure the rotor rotates smoothly. To replace the front bearing users must remove the 4 screws from the bearing retainer followed by using Special Service Tool 09950-60010 (09951-00520) to press out the bearing while using a socket wrench and press then install the new bearing using the same tool before torquing the 4 screws to 3.0 N.m (31 kgf.cm, 27 in.lbf). The process begins by using Special Service Tool 09820-00021 to separate the rear bearing cover and bearing while protecting the tan material before installation of the inside bearing cover and new bearing insertion with Special Service Tool 09820-00030 followed by an outside bearing cover installation with Special Service Tool 09285-76010.