OEM 2003 Toyota Avalon Alternator

2003 Toyota Avalon Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2003 Toyota Avalon?

  A: Service and repair operations on the alternator start with removing the rear end cover through separating the terminal insulator nut followed by the screw and three nuts and then the plate terminal and the end cover. You should first disconnect the brush holder cover before unscrewing the 5 screws of both the brush holder and the voltage regulator. The rectifier holder requires 4 screw removal and subsequent extraction of the holder itself followed by the removal of 4 rubber insulators and the seal plate. Apply torque wrench to SST (A) while tightening SST (B) clockwise to a value of 39 N.m and 400 kgf.cm and 29 ft.lbf which keeps SST (A) locked to the rotor shaft. Fix SST (C) to a vise before inserting SST (B) into SST (C) while adding the pulley nut to SST (C). After you do a half turn of SST A using the indicated direction to loosen the pulley nut, safely detach SST A and B before separating the pulley nut and pulley while keeping the generator on SST C. The removal process requires the wire clamp and four nuts and cord clip removal then using SST O9286-46011 to separate the rectifier end frame from the thrust washer. The rectifier end frame should be placed on the pulley first before installing the rotor onto it and finally placing the thrust washer between rotor and rectifier end frame before finally pressing in the rectifier end frame using a 29 mm socket wrench. Use SST O9286-46011 to mount the rectifier end frame while installing the cord clip followed by 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), then attaching the wire clamp. First install the pulley on the rotor shaft while hand-tightening the pulley nut. Next position SST (A) below a torque wrench for tightening SST (B) to 39 N.m (400 kgf.cm, 29 ft.lbf) until SST (A) remains locked to the pulley shaft. Mount SST (C) in a vise and insert SST (B) into SST (C) while applying the pulley nut to SST (C) before torquing the pulley nut to 110.5 Nm (1,125 kgf.cm, 81 ft.lbf). After which remove the generator from SST (C) and disconnect SST (A and B). Install the rectifier holder through the sequence of attaching the seal plate to the end frame followed by rubber insulator fitting to each lead wire and screw tightening to 2.9 N.m (30 kgf.cm, 26 in.lbf). Install the voltage regulator and brush holder onto their positions on the rectifier end frame and ensure proper installation direction while using 5 screws torqued at 2.0 N.m (20 kgf.cm, 18 in.lbf) tension to then cover the brush holder. Close the rear end by attaching the end cover combined with plate terminal through 3 nuts until the screw reaches 3.9 N.m (39 kgf.cm, 35 in.lbf) and nuts achieve 4.4 N.m (45 kgf.cm, 39 in.lbf) then secure the terminal insulator with 4.1 N.m (41.5 kgf.cm, 36 in.lbf). Subsequently inspect rotor smoothness. To replace the front bearing first remove the 4 screws and bearing retainer after which apply a socket wrench to press out the bearing and install a new one with SST 09950-60010 (09951-00520) then tighten the bearing retainer with its 4 screws at 3.0 N.m (31 kgf.cm, 27 in.lbf torque. SST tools should be used to remove the bearing cover (outside) and bearing with SST 09820-00021 while protecting the tan, followed by bearing cover (inside) removal and then placing the rotor with a new bearing inserted by SST 09820-00031 and finally inserting the bearing cover (outside) with SST 09285-76010.