OEM 2004 Toyota Highlander Alternator

2004 Toyota Highlander Alternator Parts Q&A

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

  A: Start repairing the alternator by using Special Service Tool 09820-63010 (09820-06010, 09820-06020) to remove the pulley through the pulley holding tool attached to a torque wrench which should be tightened clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf) until the tool attaches to the rotor shaft. Secure the adapter in a vise before you place the socket inside the adapter while also attaching the pulley nut. Wedge the pulley holding tool with counterclockwise rotation but do not exceed one half turn because excessive movement can damage the rotor shaft and so remove the generator together with the pulley nut and pulley from the adapter. Position the generator on the pulley to begin removal procedures starting with three nuts and completion by securing the terminal insulator from the rectifier end frame. Remove the two screws that fasten the brush holder assembly in 100 A versions or the plate seal and two screws in 130 A versions. Detach the generator coil assembly by removing the four bolts while using Special Service Tool 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) before taking out the washer and rotor. Measuring the generator brush holder assembly with a vernier caliper will verify its brush length exposure meets requirements for 10.5 mm (0.413 in.), unless the length falls below the minimum standard of 4.5 mm (0.177 in.). Under inspection of the generator rotor assembly examine the bearings and check for open circuit and ground while evaluating slip ring condition by testing the slip ring resistance against 1 Mohm and measuring its diameter between 14.2 to 14.4 mm (0.559 to 0.567 in.) with minimum 14.0 mm (0.551 in.). You must use Special Service Tool 09820-00021 to remove the generator rotor bearing of the 130 A version without harming the fan and install a new bearing using Special Service Tool 09820-00031 alongside Special Service Tool 09285-76010. Replace the generator drive end frame bearing if necessary and remove the existing bearing using Special Service Tool 09950-60010 (09951-00250) and 09950-70010 (09951-07100) before installing a new bearing using the same tools and securing the retainer plate by tightening four screws to 2.3 Nm (23 kgf.cm, 20 in.lbf). To reassemble the generator drive end frame users must place it on the pulley and insert the rotor with washer as well as pressing in the coil using deep socket wrenches 21 for the 100 A version or deep socket wrench 20 for the 130 A version before tightening all four bolts to 5.8 Nm (59 kgf.cm, 51 in.lbf). They installed the brush holder assembly in forward direction then secured it using two screws at 1.8 Nm (18 kgf.cm, 16 in.lbf) torque before mounting the terminal insulator according to its mounting directions. The last installation steps include fastening the rear end cover with three nuts tuned to 4.6 Nm (47 kgf.cm, 41 in.lbf) while manually attaching the generator pulley through the pulley holding tool to reach 39 Nm (400 kgf.cm, 29 ft.lbf) before tightening it further to 111 Nm (1,125 kgf.cm, 81 ft.lbf). Check that the pulley moves freely when complete.