OEM 2004 Toyota Avalon Alternator

2004 Toyota Avalon Alternator Parts Q&A

• Q: How to service and repair the alternator on 2004 Toyota Avalon?

  A: Start alternator servicing by first removing the rear end cover through a sequence of removing the nut and terminal insulator followed by the screw and three nuts then the plate terminal and end cover. Start by dismissing the brush holder and voltage regulator through removal of the 5 screws and brush holder cover. Remove the rectifier holder through an unscrewing process of 4 screws while also removing 4 rubber insulators and the seal plate. Apply the pulley holding tool Special Service Tool 09820-63011 together with a torque wrench to secure the socket against the rotor shaft through clockwise rotation to 39 Nm (400 kgf.cm, 29 ft.lbf). Turn the pulley nut counterclockwise a maximum of half a turn before discarding the generator from the adapter so it does not damage the rotor shaft and then disconnect the pulley nut and pulley. The next step involves removing the rectifier end frame through a three-step procedure of wire clamp removal followed by 4 nuts loosening and finally disconnecting the cord clip after which Special Service Tool O9286-46011 extract the rectifier end frame succession followed by the thrust washer. The procedure starts with replacing the front bearing by first unscrewing the 4 screws from the bearing retainer before pressing out the used bearing while pressing in a new bearing through the use of Special Service Tool 09950-60010 (09951-00520). Secure the bearing retainer with 4 screws by torquing them to 3.0 N.m (31 kgf.cm, 27 in.lbf). To install the rear bearing you should remove the covering components with Special Service Tool 09820-00021 then place the inside bearing cover on the rotor before inserting the new bearing with Special Service Tool 09820-00031 followed by pressing in the outside bearing cover with Special Service Tool 09285-76010. To achieve reassembly start with installing the rotor to the drive end frame then placing the rectifier end frame onto the pulley before installing the rotor. Position the thrust washer onto the rotor before using a 29 mm socket wrench to insert and hold the rectifier end frame in place. Then secure the cord clip followed by installing 4 nuts that need torquing to a value of 4.5 N.m (46 kgf.cm, 40 in.lbf) for NUT A and 5.4 N.m (55 kgf.cm, 48 in.lbf) for NUT B before applying the wire clamp. Begin by operating the pulley nut manually but finish the operation with the pulley holding tool to achieve torques of 39 N.m (398 kg.cm, 29 ft.lb) then 111 N.m (1,132 kg.cm, 82 ft.lb). To install the rectifier holder together with the seal plate and 4 rubber insulators, screw each fastener to 2.9 N.m (30 kgf.cm, 26 in.lbf). Place the brush holder cover over the brush holder after directing both components correctly on the rectifier end frame and securing each of the five screws at 2.0 N.m (20 kgf.cm, 18 in.lbf). The last step includes installing the rear end cover between the end cover and plate terminal by securing 3 nuts with a screw at 3.9 N.m (39 kgf.cm, 35 in.lbf) while the nuts have a torque of 4.4 N.m (45 kgf.cm, 39 in.lbf) and tightening the terminal insulator nut to 4.1 N.m (41.5 kgf.cm, 36 in.lbf) to achieve smooth rotor movement.