OEM 2003 Toyota Camry Alternator

2003 Toyota Camry Parts Questions & Experts Answers

• Q: How to replace and overhaul the alternator on 2003 Toyota Camry?

  A: The alternator replacement process begins with using Special Service Tool 09249 - 63010 to remove the fan and then the generator V belt. The engine wire disconnection follows removal of two bolts which hold the alternator assembly together. During installation of the generator assembly position the crank position sensor wire harness in its correct position before installing the alternator assembly and tightening the bolts according to the following specifications: M8 21 N.m (214 kgf.cm, 15 ft.lbf), M10 52 N.m (530 kgf.cm, 38 ft.lbf), wiring harness clamp 8.4 N.m (85 kgf.cm, 74 in.lbf), and alternator wire 9.8 N.m (100 kgf.cm, 7 ft.lbf) while avoiding wire harness pinch points. Employ Special Service Tool 09249 - 63010 to install the fan and generator V belt. To service the generator pulley operators must use Special Service Tool 09820 - 63010 (09820 - 06010, 09820 - 06020) secured to Special Service Tool 1 - A with a torque wrench for 39 N.m (400 kgf.cm, 29 ft.lbf) on Special Service Tool 1 - B. Secure the pulley nut to Special Service Tool 2 using a vise before you loosen it without exceeding one-half turn. Extract the alternator from Special Service Tool 2 and proceed by separating the pulley nut and pulley. Unscrew the generator brush holder assembly by breaking the nut and removing the terminal insulator then the bolt followed by three nuts and plate terminal and end cover, followed by brush cover and finally brush holder. Remove first the generator regulator assembly by unfastening the screws before detaching the generator holder with rectifier using the four screws. Remove the alternator rectifier end frame through the procedure of rubber insulator removal followed by seal plate removal and four nut uninstallation before extracting the frame with a bearing puller set. The rotor generator assembly needs to be removed through alternator washer removal before carefully retrieving the rotor from the drive end frame. You should test the continuity between terminals F and E and F and B in the generator regulator assembly before changing the voltage regulator when continuity is not correct. Vernier calipers should be used to measure slip ring diameter on the generator rotor assembly, followed by a rotor replacement when the dimension falls below specifications. Open circuits and ground issues should be checked for the slip rings, while continuity must be present between the slip rings but absent between the slip ring and rotor. The generator holder with rectifier needs a continuity check at its rectifier terminals along with an inspection of brush length which requires a new brush holder assembly if the exposed length drops below the minimum. Secure the rectifier end frame with a 17 mm socket wrench by fastening the cord clip and four nuts under specified torque standards of Nut A 4.5 N.m and Nut B 5.4 N.m. Torque values correspond to 46 kgf.cm and 55 kgf.cm respectively, or 39 in.lbf and 47 in.lbf. Mount the seal plate followed by installation of four rubber insulators onto the lead wires keeping their direction correct. Secure four screws to attach the generator holder with rectifier and tighten them to 2.9 N.m (30 kgf.cm, 26 in.lbf). Finally, install the generator regulator assembly with three screws and apply torque of 2.0 N.m (20 kgf.cm, 18 in.lbf). Apply two screws to the generator brush holder assembly at 2.0 N.m (20 kgf.cm, 18 in.lbf) torques before adding the brush cover and end cover and plate terminal using the bolt and three nuts which require Nut 4.4 N.m (45 kgf.cm, 39 in.lbf) and Bolt 3.9 N.m (39 kgf.cm, 35 in.lbf) torques and finally attach the terminal insulator with the nut to 4.1 N.m (42 kgf.cm, 36 in.lbf). The generator pulley needs Special Service Tool 09820 - 63010 (09820 - 06010, 09820 - 06020) for attachment to the rotor shaft while torquing Special Service Tool 1 - A with a torque wrench to reach 39 N.m (400 kgf.cm, 29 ft.lbf). Secure Mount Special Service Tool 2 in a vise while inserting Special Service Tool 1 - A, B followed by attaching the pulley nut before tightening the pulley nut to 111 N.m (1,125 kgf.cm, 81 ft.lbf). Then remove the alternator from Special Service Tool 2 and test for smooth pulley movement.