OEM 2004 Toyota Camry Alternator

2004 Toyota Camry Parts Questions & Experts Answers

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

  A: Service and alternator repairs must start with the removal of the generator pulley through the use of tools 09820-63010, 09820-06010, and 09820-06020. Special Service Tool (1-A) must be held under torque wrench tension while turning Special Service Tool (1-B) clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf) until it secures to the rotor shaft. Fasten Special Service Tool (2) in a vise before inserting Special Service Tool (1-A, B) into it and putting the pulley nut on. Loosen the pulley nut by following Special Service Tool (1-A) instructions but stop before the rotor shaft suffers damage. After removing the generator from Tool (2) the user should turn Tool (1-B) to separate Tool (1-A, B) and expose the pulley nut together with the generator pulley for removal. Apply the generator to the generator pulley before you take out three nuts and the rear end cover and separate the terminal insulator from the generator rectifier end frame. The generator brush holder assembly detaches after screwing out two screws followed by removing the generator coil assembly through four bolt removal and the use of Special Service Tool 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011). Use a vernier caliper to measure each brush in the generator brush holder assembly before replacement when the brush length falls below 4.5 to 10.5 mm (0.177 to 0.413 inches). Tests of the generator rotor assembly should evaluate bearing health along with open circuit, ground and slip ring quality by measuring the slip ring to rotor core resistance which must be higher than 10 k Ohm; the slip ring diameter should range from 14.0 to 14.4 mm (0.551 to 0.567 in.); any failed specifications indicate replacing the rotor. Begin inspection of the generator drive end frame bearing for deterioration before removing it from its position using the four screws and Special Service Tool 09950-60010 (09951-00250) and 09950-70010 (09951-07100) to extract it. The new bearing installation requires Special Service Tool 09950-60010 (09951-00470) and 09950-70010 (09951-07100) to be used with a press while securing the retainer plate with four screws tightened to 2.3 Nm (23 kgf.cm, 20 in.lbf). Put the generator drive end frame onto the generator pulley and add generator rotor and washer before applying precise pressure with deep socket wrench 21 on the four bolts until they reach torque of 5.8 Nm (59 kgf.cm, 51 in.lbf). To install the generator brush holder assembly begin by pushing the two brushes inward followed by insertion of a 1.0 mm (0.039 inch) pin through the brush holder hole and secure it by tightening two screws to 1.8 Nm (18 kgf.cm, 16 inch pounds). Finally remove the pin. Drivers must carefully place the generator drive end frame onto the generator pulley before adding the rotor with washer installation. It is essential to maintain correct terminal insulator alignment before securing the rear end cover by tightening its three nuts to 4.6 Nm. After positioning the generator pulley manually begin fastening its nut with Special Service Tool 09820-63010, 09820-06010, 09820-06020 using a torque wrench until it produces 39 Nm (400 kgf.cm, 29 ft.lbf) and verify that Special Service Tool remains attached to the rotor shaft.