OEM 2002 Toyota Sienna Alternator

2002 Toyota Sienna Parts Questions & Experts Answers

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

  A: The alternator service begins with disassembly where you should first remove the rear end cover by taking out the nut and terminal insulator then the screw followed by the three nuts and plate terminal and end cover. Before proceeding to detach the brush holder along with the voltage regulator you must pop off the brush holder cover followed by removing the 5 screws. You must first remove the rectifier holder by taking out its four screws as well as its four rubber insulators and the seal plate. The pulley holding tool (Special Service Tool 09820-63011) needs combination with a torque wrench to achieve 39 Nm (400 kgf.cm, 29 ft.lbf) clockwise tightening force when securing the tool against the rotor shaft. Position the adapter in a vise before inserting the socket followed by the pulley nut which must be turned counterclockwise only until a half turn while maintaining safety of the rotor shaft. First remove the generator from its adapter before taking off the socket, pulley holding tool and pulley and pulley nut. Move on to disconnect the rectifier end frame by first disconnecting all 4 nuts and cord clip then utilizing Special Service Tool 09286-46011 to separate the rectifier end frame before taking off the generator washer. To reassemble start by fitting the rotor to the drive end frame where you first attach the rectifier end frame onto the pulley followed by the rotor. The generator washer installation begins with placing it onto the rotor before applying a 29 mm socket wrench and press to gently insert the rectifier end frame while securing it with the cord clip and 4 nuts. Torque 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). Before tightening the pulley nut, manually install the pulley but finish the installation with a pulley holding tool (Special Service Tool 09820-63011) by torqueing it clockwise to 111 N.m (1,132 kg.cm, 82 ft.lb). Install the seal plate onto the rectifier end frame and then mount the 4 rubber insulators onto each lead wire before fastening the rectifier holder with 4 screws that need 2.9 N.m (30 kgf.cm, 26 in.lbf) torque. Install the 5 screws on the rectifier end frame by selecting correct holder installation direction before torquing them to 2.0 N.m (20 kgf.cm, 18 in.lbf), and complete the installation with the brush holder cover. The final installation task includes attaching the end cover together with plate terminal through 3 nuts and a screw. Torque 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) then install the terminal insulator with the nut and torque to 4.1 N.m (42 kgf.cm, 36 in.lbf). Verify smooth rotor rotation.