OEM 2003 Toyota Highlander Alternator

2003 Toyota Highlander Parts Questions & Experts Answers

• Q: How to Service and Repair a 130 A Alternator on 2003 Toyota Highlander?

  A: Service and repair operations for the 130 A alternator start with pulley removal through application of Special Service Tool 09820-63010 (09820-06010, 09820-06020) by using a torque wrench to tighten the socket clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf) until the tool securely holds the rotor shaft. The adapter needs to go into a vise followed by the socket insertion to connect the pulley nut while counterclockwise turning the nut at most half a revolution to protect the rotor shaft from damage. First detach the pulley nut and pulley then remove the socket and pulley holding tool followed by the generator from its adapter. You must disassemble the generator brush holder unit by loosening 3 nuts and end cover followed by the rear seal plate and 2 screws then the brush holder followed by the front seal plate. Use the Special Service Tool 09950-40011 (along with 6 other tools) to disassemble the coil assembly when you have removed all its four bolts. Before dropping it you must carefully remove the alternator washer from the rotor and then remove the rotor from the drive end frame. The inspection of a rotor requires an ohmmeter to verify slip ring continuity while checking the standard resistance of 2.3 - 2.7 ohm at 20 degrees Celsius (68 degrees Fahrenheit). If no continuity exists the rotor needs replacement. A continuity test between the alternator slip ring and rotor should be performed to check for ground; replace the rotor if the test shows continuity. The acceptable length range for the slip ring measurement must be 14.2 - 14.4 mm (0.559 - 0.567 in.) while maintaining a minimum dimension of 14.0 mm (0.551 in.) to prevent replacement. Ensure the brush holder assembly replacement when the brush length measurement falls outside the specified range of 9.5 - 11.5 mm (0.374 - 0.453 in) and meanwhile exceeds the minimum requirement of 4.5 mm (0.177 in). The generator rotor assembly requires placing back onto position followed by installation of the alternator washer. Apply a 17 mm socket wrench when pressing in the coil assembly until it becomes stable with 4 bolts tightened to 5.8 N.m (59 kgf.cm, 51 in.lbf). Install the generator brush holder assembly through a sequence that includes placing the front seal plate and screwing two screws along with giving a 1.8 N.m (18 kgf.cm, 16 in.lbf) torque to the brush holder before adding the rear seal plate and installing three nuts with an end cover at 4.6 N.m (47 kgf.cm, 41 in.lbf). Install the generator pulley with Special Service Tool 09820-63010 (09820-06010, 09820-06020) by first loosely tightening its pulley nut by hand then apply the torque wrench to 39 Nm (400 kgf.cm, 29 ft.lbf) and maintain the tool's hold on the pulley shaft. Insert the socket into the vise-mounted adapter followed by the pulley nut attachment before torque application will reach 111 Nm (1,125 kgf.cm, 81 ft.lbf). Once you remove the generator from the adapter check the pulley for smooth movement.