OEM 2001 Toyota RAV4 Alternator

2001 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2001 Toyota RAV4?

  A: Start the alternator repair and servicing process by separating each part from its components by first untightening the nut that locks down the terminal insulator to access the rear end cover (then proceed to detach the bolt and 3 nuts along with the plate terminal and end cover and brush holder cover). Begin service and repair of the alternator through brush holder and voltage regulator removal using the 5 screws and seal plate detached from the rectifier end frame. Remove the rectifier holder through the process of unscrewing four screws and disengaging the rubber insulators. Hold the pulley using Special Service Tool 09820-63010 and a torque wrench that requires clockwise application of 39 Nm (400 kgf.cm, 29 ft.lbf) to secure the tool to the rotor shaft. Then open the pulley nut counterclockwise without going beyond half a turn. Unplug the generator from the adapter before removing its pulley nut along with pulley. Detach the rectifier end frame using Special Service Tool 09286-46011 by removing 4 nuts and wire clip then separate the frame from the rotor allowing you to extract the generator washer. The assembly process includes inserting the rotor into the drive end frame followed by placing the generator washer on the rotor before pushing in the rectifier end frame using a 29 mm socket wrench to fasten it with wire clip and torqued 4 nuts to specified settings. Begin installed pulley hand-tight by placing the nut then apply the pulley holding tool to torque up to 111 N.m at 1,132 kg.cm and 82 ft.lb. Place the rectifier holder with its correct installation direction and attach 4 rubber insulators before tightening 4 screws to 2.9 N.m (30 kg.cm, 26 in.lb). Secure the rectifier end frame with 5 screws at 2.0 N.m (20 kg.cm, 18 in.lb) while you mount the brush holder and its cover before using a bolt and 3 nuts to install the end cover and plate terminal at specified torques. A final step should include testing the rotor movement for easy smooth operation. The front bearing replacement process starts by eliminating the 4 screws and bearing retainer then using Special Service Tool 09950-60010 (09951-00350), 09950-70010 (09951-07100) for bearing removal and insertion of a new one before finishing with 4 screws at 3.0 N.m (31 kg.cm, 27 in.lb) torque. When replacing the rear bearing dependent on Special Service Tool 09821-00021 to take out the bearing cover and bearing before placing the inner bearing cover onto the rotor through the bearing installation using Special Service Tool 09820-00030 and finally applying Special Service Tool 09825-76010 to set the outer bearing cover.