OEM 2003 Toyota Corolla Alternator

2003 Toyota Corolla Parts Questions & Experts Answers

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

  A: Use Special Service Tool 09820-63010 (09820-06010, 09820-06020) together with a torque wrench to hold the pulley holding tool while you turn the socket clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf). The tool needs to be tightened securely to the rotor shaft. Before loosening the pulley nut with counterclockwise rotation use the pulley holding tool while preventing the shaft from exceeding half a turn to safeguard the rotor shaft. The generator first needs removal from the adapter followed by the removal of the socket and pulley holding tool. The sequence continues with removing the pulley nut and pulley. Proceed with the generator brush holder assembly disassembly starting with the nut and terminal insulator followed by the screw and nut and terminal plate and the two nuts together with the rear end cover and then the brush cover and the two screws securing the brush holder before finishing with the removal of the plate seal. The process of removing the generator regulator assembly requires unfastening its three screws and taking off the regulator. Begin removing the generator holder with rectifier by proceeding to remove the four screws then taking out the plate seal from the rectifier end frame followed by the four terminal insulators, four nuts, and cord clip, using Special Service Tool 09286-46011 to detach the rectifier end frame. Take off the washer from the rotor followed by removing the rotor from the drive end frame. You must check the generator regulator assembly to verify the presence of continuity between terminals F and B and F and E while ensuring the continuity should flow in one way. Hospital staff must measure both slip ring diameters and check their continuity status before measuring the ring diameter again to verify it stays between 14.2 mm and 14.4 mm (0.559 in. and 0.567 in.) while being greater than the minimum requirement of 12.8 mm (0.504 in.). Verify that the exposed brush length measures from 9.5 - 11.5 mm (0.374 - 0.453 in.) while exceeding 1.5 mm (0.059 in.). The procedure to install the generator rotor assembly begins by setting the rotor onto the drive end frame followed by washer installation before using socket wrench 29 and press to carefully secure the rectifier end frame by attaching the cord clip and tightening four nuts to specified torques of Nut A at 4.5 Nm (46 kgf.cm, 40 in.lbf) and Nut B at 5.4 Nm (55 kgf.cm, 48 in.lbf). The installation begins with installing the generator holder with rectifier through four screws providing 2.9 Nm (30 kgf.cm, 26 in.lbf) torque. Following this, the generator regulator assembly receives three screws tightened to 2.0 Nm (20 kgf.cm, 18 in.lbf) torque. You must install the plate seal onto the brush holder followed by attaching two screws at 2.0 Nm (20 kgf.cm, 18 in.lbf) before placing the brush cover and sealing it with two nuts at 4.4 Nm (45 kgf.cm, 39 in.lbf). During assembly, attach the terminal plate through screw and nut applications that must generate 3.9 Nm (40 kgf.cm, 35 in.lbf) and 4.4 Nm (45 kgf.cm, 39 in.lbf) torque respectively before installing the terminal insulator with 4.1 Nm (42 kgf.cm, 36 in.lbf) torque. Finally, install the generator pulley by hand-tightening the pulley nut, then using the pulley holding tool with a torque wrench, tighten the socket clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf), ensuring the tool is secured to the pulley shaft, followed by clamping the adapter in a vise, inserting the socket into the adapter, and attaching the pulley nut, tightening it to 111 Nm (1,125 kgf.cm, 81 ft.lbf), before removing the generator from the adapter, turning the socket to detach the socket and pulley holding tool, and checking that the pulley moves smoothly.