OEM 2005 Toyota Avalon Alternator

2005 Toyota Avalon Parts Questions & Experts Answers

• Q: How to overhaul the alternator on 2005 Toyota Avalon?

  A: Start the alternator overhaul by first detaching the generator with clutch pulley through screwdriver removal of the generator pulley cap followed by mounting and installing the Rotor Shaft Holding Tool (SST: 09820-63020) along with the Clutch Pulley Wrench. Mount the Rotor Shaft Holding Tool with a vise installation and then install the generator in counterclockwise direction with SST. You must first loosen the generator pulley using the Clutch Pulley Wrench while rotating it clockwise before you can remove the generator along with its pulley from the rotor shaft. Remove the generator rear end cover by first undoing its 3 nuts and then separate the terminal insulator using two screws on the generator brush holder assembly. You need to detach the generator coil assembly by using SST (09950-40011, 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) to remove the four bolts and the generator washer. Check the generator with clutch pulley rotation by verifying its counterclockwise motion while it should not turn clockwise. Use vernier calipers to measure the brush length of the exposed area while confirming it exceeds 10.5 mm (0.413 in.) but remains above the minimum limit of 4.5 mm (0.177 in.). A thorough check of the generator's rotor bearing wear condition requires an ohmmeter test to detect open and short circuits with specified resistance ranges. The slip ring diameter measurement should be at least 14.0 mm (0.551 in.). Operate the inspection of the generator drive end frame bearing by removing it with 4 screws and applying a hammer with SST (09950-60010, 09951-00250, 09950-70010, 09951-07100) to tap it out. Depress a new generator drive end frame bearing into position through SST tools which will be secured with the bearing retainer and torqued 4 screws to 2.3 N.m (23 kgf.cm, 20 in.lbf). Start by installing the generator rotor assembly together with its washer before you use a deep socket wrench (21 mm) to press and bolt (torque to 5.8 N.m or 59 kgf.cm or 51 in.lbf) the generator coil assembly. A diameter 1.0 mm pin receives insertion for brush retention during the installation of two screws torque-set at 1.8 N.m (18 kgf.cm, 16 in.lbf). Once ready, remove the pin. Place the terminal insulator in proper position and then put on the rear end cover by tightening 3 nuts to 4.6 N.m (47 kgf.cm, 41 in.lbf). Following the above steps, reinstall the generator while using the Rotor Shaft Holding Tool and Clutch Pulley Wrench to achieve 87 N.m (891 kgf.cm, 64 ft.lbf) torque on the generator pulley with a torque wrench of 380 mm (14.96 in.) fulcrum length. Conduct a smoothness check on the generator pulley before placing the new generator pulley cap.