OEM 2001 Toyota Sienna Alternator

2001 Toyota Sienna Parts Questions & Experts Answers

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

  A: The first step for servicing and repairing an alternator involves removing its rear end cover through nut and terminal insulator removal followed by screw and 3 nuts and plate terminal and end cover complete separation. Service starts with brush holder and voltage regulator removal through brush holder cover screws and 5 screws. Next move on to the rectifier holder through a screwing process that requires removal of four screws and four rubber insulators and one seal plate. Special Service Tool 09820-63010 enables you to secure the pulley using a torque wrench to reach 39 Nm of torque while the tool mounts directly onto the rotor shaft. Install the generator within a vise and loosen the pulley nut in a counterclockwise direction only half a turn to prevent damage to the rotor shaft while mounting the adapter. First remove the pulley nut from the pulley followed by the pulley alongside the socket holding tool. Next step includes removing the generator from the adapter. Remove the rectifier end frame by first removing four nuts and the cord clip followed by using Special Service Tool 09286-46011 to detach the frame and subsequently removing the generator washer. The rotor needs to be installed to the drive end frame through a process which starts with setting the rectifier end frame onto the pulley followed by the rotor. Use a 29 mm socket wrench to install the rectifier end frame several stages at a time until secure with the cord clip and 4 nuts while torquing 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). Install the pulley with hand-torque on the nut before applying Special Service Tool 09820-63011 to torque it at 111 N.m (1,132 kg.cm, 82 ft.lb) while maintaining a secure fit between the tool and the pulley shaft. Install the seal plate to the rectifier end frame and position 4 rubber insulators on the lead wires then secure the rectifier holder with 4 screws which require torquing to 2.9 N.m (30 kgf.cm, 26 in.lbf). Follow by placing the voltage regulator and brush holder on the rectifier end frame with attention to the holder's correct direction and installing 5 screws while torquing them to 2.0 N.m (20 kgf.cm / 18 in.lbf). Before concluding installation, position the brush holder cover and attach the end cover and plate terminal with 3 nuts and one screw while torquing the screw to 3.9 N.m (39 kgf.cm, 35 in.lbf) and the nut to 4.4 N.m (45 kgf.cm, 39 in.lbf) before torquing the terminal insulator nut to 4.1 N.m (42 kgf.cm, 36 in.lbf). Make sure the rotor moves without any unusual movements during its rotation.