OEM 2001 Toyota MR2 Spyder Alternator

2001 Toyota MR2 Spyder Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2001 Toyota MR2 Spyder?

  A: Service and repair of the alternator starts with rear end cover removal through terminal insulator nut and bolt followed by 3 nuts and plate terminal and end cover. You must start by removing all components of the brush holder and voltage regulator through the procedure of unfastening the brush holder cover followed by removing 5 screws, brush holder and voltage regulator, and then detaching the seal plate from the rectifier end frame. Begin by removing the rectifier holder screws after which follow the removal of both rectifier holder and its 4 rubber insulators. Use Special Service Tool 09820-63010 together with a torque wrench to tighten the socket so it reaches 39 Nm (400 kgf.cm, 29 ft.lbf) while holding the pulley against the rotor shaft. Insert the adapter into a vise then place the socket inside before connecting the pulley nut while unwinding it backward with caution until reaching only half a turn to prevent rotor shaft damages. The adapter procedure begins by disconnecting the generator from its position before removing the socket then tool and pulley holding device and lastly removing both the pulley nut and pulley. Disassemble the rectifier end frame by first unfastening the 4 nuts along with the wire clip before detaching the rectifier end frame using Special Service Tool 09286-46011 and later removing the generator washer from the rotor. To rebuild the device first secure the rotor inside the drive end frame then position the generator washer onto the rotor before applying the rectifier end frame through a 29 mm socket wrench which must be secured by wire clip and four nuts while tightening Nut A to 4.5 N.m (46 kgf.cm, 40 in.lbf) and Nut B to 5.4 N.m (55 kgf.cm, 48 in.lbf). Use your hands to tighten the pulley nut first but then apply the torque wrench to the pulley holding tool for tightening the pulley nut up to 39 N.m (400 kg.cm, 29 ft.lb). Make sure the torque tool grasps the pulley shaft securely. The generator requires removal from the adapter once the pulley nut receives a torque of 111 N.m (1,132 kg.cm, 82 ft.lb). Mount the rectifier holder with 4 rubber insulators set in their proper direction then fasten the unit with 4 screws tightened to 2.9 N.m (30 kgf.cm, 26 in.lbf). Begin by placing the seal plate onto the rectifier end frame before installing the voltage regulator and brush holder with proper direction in mind and securing it with 5 screws torqued to 2.0 N.m (20 kgf.cm, 18 in.lbf). After installing the rear end cover and plate terminal secured with the bolt then 3 nuts the nut should be torqued to 4.4 N.m (45 kgf.cm, 39 in.lbf) and the bolt presented 3.9 N.m (39 kgf.cm, 35 in.lbf). The final step is to install the terminal insulator with its nut torqued to 4.1 N.m (42 kgf.cm, 36 in.lbf) followed by a smooth rotor rotation verification. The front bearing replacement process starts with unscrewing four retaining bolts and removing the bearing retainer. Install the Special Service Tool 09950-60010 (09951-00350) and 09950-70010 (09951-07100) with the press to remove and reinstall new bearings with comparable tools. After installation of the bearing retainer use 4 screws which need to be torqued to 3.0 N.m (31 kgf.cm, 27 in.lbf). The process to replace the rear bearing begins with using Special Service Tool 09820-00021 to eliminate both the bearing cover (outside) and bearing while safeguarding the fan before removing the bearing cover (inside) to attach it to the rotor. First install a new bearing with the press using Special Service Tool 09820-00030 and conclude by inserting the bearing cover (outside) using Special Service Tool 09285-76010.