OEM 2001 Toyota Highlander Alternator

2001 Toyota Highlander Parts Questions & Experts Answers

• Q: How to service and repair the 130 A alternator on 2001 Toyota Highlander?

  A: Service and repair of the 130 A alternator starts with pulley removal through tool Special Service Tool 09820-63010 (09820-06010, 09820-06020) that needs to be held by a torque wrench while tightening its socket clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf) until it properly engages with the rotor shaft. Place the adapter under a vise clamp then insert the socket in position before applying the pulley nut. Avoid rotor shaft damage by turning the pulley nut counterclockwise but no more than a half rotation. First remove the generator from its adapter and then take off the socket followed by both the pulley holding tool and finally the pulley nut before removing the pulley. Peel away the generator brush holder assembly by disassembling respectively the 3 nuts and end cover and also separating the rear seal plate and the two screws and the brush holder and finally stripping away the front seal plate. Use Special Service Tool 09950-40011 (which includes 6 individual tools) to detach the coil assembly after removing its 4 bolts. Remove the alternator washer from the rotor and separate the rotor from the drive end frame with great caution towards preventing it from falling. An ohmmeter can detect open circuit conditions between slip rings during inspection of the rotor for continuity checks at 20 degrees Celsius (68 degrees Fahrenheit). If the test fails to detect continuity replace the rotor. Check for ground by inspecting that the rotor exhibits no continuity with the slip ring then replace the rotor when continuity occurs. Use vernier calipers to measure slip ring diameter which must be between 14.2 and 14.4 mm (0.559 to 0.567 inches) but not less than 14.0 mm (0.551 inches) for replacement prevention. Check the brush exposure measurement because it should be within 9.5 - 11.5 mm (0.374 - 0.453 in.) range and not lower than 4.5 mm (0.177 in.). If necessary replace the brush holder assembly. The installation of generator rotor assembly requires first placing it back into place before adding the alternator washer. The coil assembly can be installed by using a 17 mm socket wrench for gradual pressing before securing the assembly with four bolts at 5.8 N.m (59 kgf.cm, 51 in.lbf). The installation of the generator brush holder assembly involves placing the front seal plate followed by screwing in two screws while tightening the brush holder to 1.8 N.m (18 kgf.cm, 16 in.lbf). Afterward, add the rear seal plate and secure it with three nuts and an end cover at 4.6 N.m (47 kgf.cm, 41 in.lbf). Use Special Service Tool 09820-63010 (09820-06010, 09820-06020) to hand-tighten the pulley nut before torquing it to 39 Nm (400 kgf.cm, 29 ft.lbf) while working on the pulley shaft. Place the adapter into a vise for fixing then insert the socket followed by tightening the pulley nut clockwise to 111 Nm (1,125 kgf.cm, 81 ft.lbf) until removal of the generator from the adapter followed by a test of pulley smooth operation.