OEM 2002 Toyota RAV4 Alternator

2002 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2002 Toyota RAV4?

  A: Service and repair of the alternator starts from disassembly which includes removing the rear end cover by unscrewing its nut and terminal insulator along with its bolt and thread terminals and end cover and brush holder cover. Remove the brush holder along with voltage regulator by taking out five screws while unmounting the rectifier end frame seal plate. The next step involves removing the rectifier holder after unscrewing its 4 screws together with the rubber insulators from the setup. Special Service Tool 09820-63011 must be used to hold the pulley through a torque wrench which should clockwise tighten the socket to 39 Nm (400 kgf.cm, 29 ft.lbf) while the rotor shaft stays secured. Fix the adapter within a vise before placing the socket and attaching the pulley nut while turning it clockwise up to half a turn because excessive rotation could damage the rotor shaft. The procedure for generator adapter removal consists of first removing the socket and pulley holding tool then removing the pulley nut and pulley. Remove the rectifier end frame by detaching its 4 nuts and wire clip through utilization of Special Service Tool 09286-46011 and then extract the generator washer from the rotor. To reassemble the system begin by installing the rotor onto the drive end frame followed by adding the generator washer onto the rotor and pressing in the rectifier end frame with a 29 mm socket wrench and securing it through wire clip installation with 4 nuts which need torquing to 4.5 N.m (46 kg.cm, 40 in.lb) if no clip is used or 5.4 N.m (55 kg.cm, 48 in.lb) if the wire clip is present. Begin by tightening the pulley nut by hand before using the pulley holding tool to torque the nut first to 39 N.m then to 111 N.m. Affix the rectifier holder to its mounting position after adapting the 4 rubber insulators and tighten all screws to 2.9 N.m (30 kg.cm, 26 in.lb). Mount five screws onto the rectifier end frame to hold the seal plate, voltage regulator and brush holder while torquing them to 2.0 N.m (20 kg.cm, 18 in.lb). The steps to install the rear end cover start with placing the brush holder cover followed by attaching the end cover and plate terminal bolt and 3 nuts which require torquing to 4.4 N.m (45 kg.cm, 39 in.lb) for the nuts followed by 3.9 N.m (39 kg.cm, 35 in.lb) for the bolt and finally torquing the terminal insulator nut to 4.1 N.m (42 kg.cm, 36 in.lb). The final step should be a smooth operation of the rotor. Front bearing replacement requires removal of the bearing retainer's 4 screws before applying Special Service Tools 09950-60010 (09951-00350) or 09950-70010 (09951-07100) to press out the old bearing. Install this new bearing with the same tools after which the bearing retainer should be reinstalled with 4 screws torqued to 3.0 N.m (31 kg.cm, 27 in.lb). Installation of a new bearing for the rear section requires Special Service Tool 09821-00021 to remove the bearing cover and Special Service Tool 09820-00031 to press in the replacement bearing. The procedure ends by using Special Service Tool 09825-76010 to push in the exterior bearing cover.