OEM 2003 Toyota MR2 Spyder Alternator

2003 Toyota MR2 Spyder Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2003 Toyota MR2 Spyder?

  A: The service and repair process of the alternator starts with dismantling the rear end cover through a sequence of nut removal followed by terminal insulator removal and further removal of bolt and three nuts and plate terminal and end cover. After removing key components like brush holder covers and 5 screws, brush holder, voltage regulator, one must take off the seal plate from the rectifier end frame. First remove the rectifier holder by taking out the 4 screws and the holder and then remove the 4 rubber insulators. The pulley removal process begins with installing SST (A) under torque wrench control while using SST (B) to fit clockwise to 39 N.m (400 kgf.cm, 29 ft.lbf) until SST (A) securely attaches to the rotor shaft. SST (C) should be mounted in a vise before inserting SST (B) inside it and adding the pulley nut. Coordinate SST (A) for pulley nut loosening through the indicated direction before the generator should be extracted from SST (C) while eliminating the pulley nut and pulley. SST 09286-46011 will be needed to extract the rectifier end frame from the rotor after removal of its four nuts and wire clip. The generator washer will also need to be taken out at this time. Reassembly involves installing the rotor to the drive end frame first then adding the generator washer followed by rectifier end frame installation through a 29 mm socket wrench process while using wire clips and 4 nuts which need to be tightened to 4.5 N.m (46 kgf.cm, 40 in.lbf) on Nut A and 5.4 N.m (55 kgf.cm, 48 in.lbf) on Nut B. You should install the pulley starting with hand tightening the nut before torquing it to 39 N.m (400 kgf.cm, 29 ft.lbf) while keeping SST (A) safely attached to the pulley shaft. Attach SST (C) to the vise and fasten the pulley nut to SST (C) before torquing the pulley nut to 111 N.m (1,125 kgf.cm, 81 ft.lbf). Install the rectifier holder by connecting its 4 rubber insulators in the correct direction and tighten 4 screws to 2.9 N.m (30 kgf.cm, 26 in.lbf). The seal plate should be placed onto the rectifier end frame before adding the voltage regulator and brush holder followed by screw installation with each screw torqued to 2.0 N.m (20 kgf.cm, 18 in.lbf) then covering the brush holder. Install the rear end cover along with the plate terminal before torquing the 3 nuts to 4.4 N.m and the bolt to 3.9 N.m. Finish by torquing the insulator nut to 4.1 N.m and testing rotor smooth rotation. The front bearing replacement process requires removal of the bearing retainer through 4 screw removal followed by bearing extraction using SST 09950-60010 (09951-00350) and 09950-70010 (09951-07100). Afterward, insert a new bearing using SST 09950-60010 (09951-00530) and 09950-70010 (09951-07100) then reinstall the bearing retainer with 4 screws tightened to 3.0 N.m (31 kgf.cm, 27 in.lbf). The rear bearing installation process requires SST 09820-00021 for bearing cover and bearing removal while safeguarding the fan structure. Afterward, fit the inside bearing cover to the rotor followed by bearing insertion with SST 09820-00030 and final bearing cover placement through SST 09285-76010.