OEM 2003 Toyota Land Cruiser Alternator

2003 Toyota Land Cruiser Parts Questions & Experts Answers

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

  A: Service and repair of the alternator begins by disassembling it through screw and cover removal of the 3 screws from the rear end and 3 nuts from the end cover before taking off the terminal insulator. The repair of an alternator begins with unfastening the rear seal plate from the brush holder followed by removing its 2 screws and brush holder and finally removing the front seal plate from the coil assembly. Use the pulley holding tool Special Service Tool 09820-63010 connected to a torque wrench to apply 39 Nm (400 kgf.cm, 29 ft.lbf) clockwise torque on the socket when securing it to the rotor shaft. Install the adapter within a vise then slide in the socket before putting on the pulley nut to the adapter. The tool needs counterclockwise adjustment but should not rotate beyond a half-turn to safeguard the rotor shaft. Take off the generator from the adapter and use the socket to remove both the socket and pulley holding tool followed by taking out the pulley nut and pulley. The removal procedure requires Special Service Tool 09950-4001 1 (with components 09951-04020 0, 09952-0401 0, 09953-0402 0, 09954-0401 0, 09955-0407 1, 09958-0401 1) to extract the coil assembly followed by the removal of the generator washer. The process for front bearing replacement starts by removing four screws along with the bearing retainer and bearing. Next, use Special Service Tool 09950-60010 (09951-00250) and a hammer for bearing removal followed by using Special Service Tools 09950-60010 (09951-00470) and 09950-70010 (09951-07100) to install a new bearing. Put back the bearing retainer using 4 screws while torquing them to 2.6 N.m (27 kgf.cm, 23 in.lbf). The front bearing repair sequence involves using Special Service Tool 09820-00021 to eliminate the bearing cover and bearing before applying Special Service Tool 09820-00031 to push the new bearing into place. The specialist tool 09285-76010 finishes the operation by inserting the bearing cover within the specified area. Once the drive end frame meets the pulley position install the rotor followed by the generator washer to press in the coil assembly through Special Service Tool 09285-76010 while securing with 4 bolts tightened to 5.8 N.m (59 kgf.cm, 51 in.lbf). Before tightening the pulley nut expand the Special Service Tool 09820-63010 to 39 N.m (400 kg.cm, 29 ft.lb) and verify its installation security. First fit the adapter into a vise after which insert the socket followed by attaching the pulley nut before torquing the pulley nut to 111 N.m (1,132 kg.cm, 82 ft.lb). Start by separating the generator from the adapter before detaching the socket along with the pulley holding tool. First position the rear seal plate on the coil assembly before installing the brush holder which has its pin pointed upwards followed by torquing the two screws to 1.8 N.m (18 kgf.cm, 16 in.lbf). Check that the brush holder pins align with the back seal plate holes before continuing. After installing the terminal insulator, place the end cover in position then tighten both front and rear end cover screws to 4.6 N.m (47 kgf.cm, 41 in.lbf). Check for normal rotation of the rotor during installation.