OEM 2004 Scion xA Alternator

2004 Scion xA Alternator Parts Q&A

• Q: How to overhaul the alternator assembly on 2004 Scion xA?

  A: The generator assembly overhauling process begins with pulley removal by utilizing Special Service Tool 09820-63010 (09820-06010, 09820-06020) to connect the tool to the rotor shaft and applying a torque of 39 Nm (400 kgf.cm, 29 ft.lbf) to the socket while turning it clockwise. Tighten the pulley nut counterclockwise until it reaches a half turn then you can detach the generator from its adapter while also taking out the pulley nut and pulley. You can start by disconnecting the rear end cover where you first remove the nut followed by the terminal insulator and bolt and three nuts and plate terminal. Separate the generator brush holder from the generator regulator by removing the brush holding cover and unscrewing screws and proceeding to remove all three screws from the regulator. Use Special Service Tool 09286-46011 to detach the generator holder with rectifier through four screw removal then extract the generator rectifier end frame by discarding four rubber insulators and the seal plate with four nuts alongside the clip code. You should start rotor assembly removal by taking away both the generator washer and then gently pull out the rotor from the drive end frame. The generator regulator assembly should be checked for proper functioning while testing the continuity between F to B and F to E terminals. The generator rotor assembly between slip rings should have 2.1 to 2.5 Ohm resistance at 20 degrees Celsius (68 degrees Fahrenheit) and must have proper ground continuity. The diameter of the slip ring must be measured with vernier calipers to check it stays within the accepted range of 14.2 to 14.4 mm (0.559 to 0.567 in.) and exceeds 12.8 mm (0.504 in.). Check the bearing wear and perform a replacement when needed on the generator rotor system. An ohmmeter assessment should be performed on both positive and negative rectifiers of the generator holder with rectifier to check for proper functionality. The stator coil requires testing for open circuits while checking for ground continuity before replacing the generator assembly. Check the brush length exposure measuring 9.5 to 11.5 mm (0.374 to 0.453 in.) while being at least 4.5 mm (0.177 in.) since this determines brush holder assembly replacement eligibility. The installation process of the generator rotor assembly requires you to return the rotor along with the washer into its proper position. The generator rectifier end frame installation requires a 19 mm socket wrench for pressing in while securing it with four nuts and clip code at torque specifications. Apply the seal plate and rubber insulators while installing them according to their designated orientation. Reattach the generator holder with rectifier through four screws while keeping to specified torque values then connect the generator regulator assembly through three screws followed by two screws for the generator brush holder assembly with correct installation direction. Connect the rear end cover and terminal insulator where specified torques apply followed by generator pulley installation through hand-tightening the pulley nut before achieving final torque of 111 Nm (1,125 kgf.cm, 81 ft.lbf) using the holding tool to check smooth wheel movement.