OEM 2005 Scion tC Alternator

2005 Scion tC Parts Questions & Experts Answers

• Q: How to overhaul the alternator on 2005 Scion tC?

  A: Start the alternator overhaul by using Special Service Tool 09820-63011 (09820-06010, 09820-06021) to detach and torque-tighten Special Service Tool 1-B to the stated specifications while installing Special Service Tool 1-A onto the generator rotor shaft at 39 N.m (400 kgf.cm, 29 ft.lbf). Special Service Tool should mount to the generator rotor shaft and then Special Service Tool 2 should clamp into a vise. Insert both Special Service Tool 1-A and 1-B into Special Service Tool 2 to perform the generator pulley nut fixation. Use Special Service Tool 1-A to slowly turn the generator pulley nut in the recommended direction just until you reach a half-turn since further rotation may damage the generator rotor shaft. After removing Special Service Tool 2 the generator receives the sequence of fixing Special Service Tool 1-B the user then looses Special Service Tool 1-A to extract both tools from the generator before removing the generator pulley nut and pulley. Place the generator on the generator pulley after which you should remove the 3 nuts that secure the generator rear end cover and then remove the terminal insulator before taking out the generator brush holder with its 2 screws. The generator drive end frame needs Special Service Tool 09950-40011 (along with 6 other tools) to remove the 4 bolts and bolt and cord clip before the generator rotor can be separated from the generator rectifier end frame and the washer extracted. The generator brush holder assembly requires inspection through vernier caliper measurement of brush length which must be between 9.5 to 11.5 mm (standard) and not less than 4.5 mm (minimum). Replace if necessary. Measure the resistance between slip rings with an ohmmeter at 20 degrees Celsius (68 degrees Fahrenheit) temperature for between 2.3 to 2.7 Ohms and perform a resistance check between slip rings and rotor core above 1 MOhm then replace if not officially specified. Check the diameter of the slip ring that should measure between 14.2 to 14.4 mm (minimum 14.0 mm) while inspecting its bearing for any roughness or wear requiring replacement when present. Check the appearance of the generator drive end frame bearing then replace it if needed by removing four screws and the bearing retainer plate followed by using Special Service Tools 09950-60010 (09951-00250) and 09950-70010 (09951-07100) to push out the bearing before using 09950-60010 (09951-00470) and 09950-70010 (09951-07100) to press in a new bearing into the frame. Screw the bearing retainer plate into the generator drive end frame cutouts using its 4 screws until they reach 2.26 N.m (25 kgf.cm, 20 in.lbf) tightness. Install the generator rotor assembly by following these steps: Position the generator drive end frame onto the generator pulley, apply the washer onto the generator rectifier end frame then place the generator rotor onto the generator rectifier end frame using a 32 mm socket wrench while pressing slowly until reaching the end frame. Next, tighten all 4 bolts to 5.8 N.m (60 kgf.cm, 51 in.lbf) and install the cord clip with its bolt at 4.56 N.m (45 kgf.cm, 40 in.lbf). The generator brush holder receives the 2 brushes followed by a pin (1.0 mm (0.039 in.) diameter) insertion before attaching the brush holder with 2 screws at a torque of 1.76 N.m (15 kgf.cm, 16 in.lbf). The pin must be removed afterward to install the terminal insulator on the rectifier end frame followed by generator rear end cover installation with 3 nuts at 4.6 N.m (45 kgf.cm, 41 in.lbf). The generator pulley installation process combines manual generator pulley nut tightening with subsequent torque tightening of Special Service Tool 1-B to specified values then follows with the use of Special Service Tool 1-A on the generator rotor shaft to reach 39 N.m (400 kgf.cm, 29 ft.lbf). Utilize the vise to clamp Special Service Tool 2 while inserting Special Service Tool 1-A and B into Special Service Tool 2 followed by installation of the generator pulley nut into Special Service Tool 2 before turning Special Service Tool 1-A to achieve 110.3 N.m (1,125 kgf.cm, 82 ft.lbf). After extracting the generator from Special Service Tool 2 it becomes necessary to fix Special Service Tool 1-B while opening Special Service Tool 1-A before taking both tools off the generator. Ensure the generator pulley operates without resistance.