OEM 2002 Toyota 4Runner Alternator

2002 Toyota 4Runner Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2002 Toyota 4Runner?

  A: Service and repair of the alternator begins with removing the rear end cover through a process starting with terminal insulator and nut removal followed by end cover and three nuts. Detach the brush holder by disassembling the 2 screws followed by the brush holder and cover then strip off the brush holder cover. You need to unscrew three screws to remove the voltage regulator after which you can take out the rectifier holder by taking out four screws and four rubber insulators. The pulley demands Special Service Tool 09820-63011 which allows for torque wrench use to tighten the socket clockwise up to 39 Nm (400 kgf.cm, 29 ft.lbf) against the rotor shaft. Mount this adapter to a vise while installing the generator. Then use the tool so that it can turn in a counterclockwise direction to loosen the pulley nut until you reach half its total rotation while watching out for any harm to the rotor shaft. Check that the generator stays on the adapter before removing its socket and pulley holding tool and the pulley nut. The rectifier end frame removal starts by removing its 4 nuts and using Special Service Tool 09286-46011 before detaching the generator washer from the frame with snap ring pliers. The rectifier end frame should be installed onto the pulley and the rotor fitted to the drive end frame before securing the rectifier frame properly while maintaining correct orientation of the generator washer. A 29 mm socket wrench must be used to press and tighten the rectifier end frame with 4 nuts achieving a torque reading of 4.5 N.m (45 kgf.cm, 39 in.lbf). Use Special Service Tool 09820-63010 to rotate the pulley shaft clockwise until it reaches 39 Nm (400 kgf.cm, 29 ft.lbf) while performing this operation with the tool secured directly on the pulley shaft. The generator requires a pulley nut torque of 110.5 N.m (1,128 kgf.cm, 81 ft.lbf) before removing it from the adapter and socket tool with the pulley holding tool. Secure the rectifier holder with 4 rubber insulators placed onto lead wires and fasten it with 4 screws applying torque of 2.0 N.m (20 kgf.cm, 18 in.lbf). Install the brush holder cover onto the brush holder followed by attaching the voltage regulator and brush holder to the rear end frame while checking the cover maintains a 1 mm (0.04 in.) space from the connector during tightening of the 5 screws. Secure the rear end cover by using 3 nuts that require 4.5 N.m torque force (45 kgf.cm, 39 in.lbf) and fasten the terminal insulator through a nut torqued at 4.1 N.m (42 kgf.cm, 36 in.lbf) to allow smooth rotor rotation.