OEM 2005 Toyota Corolla Alternator

2005 Toyota Corolla Parts Questions & Experts Answers

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

  A: The first step in altering the alternator demands pulley removal with Special Service Tools 09820-63010 and 09820-06010 and 09820-06020. Clamp the pulley holding tool to the rotor shaft using a torque wrench before tightening the socket clockwise until it reaches 39 Nm (400 kgf.cm, 29 ft.lbf). The pulley nut needs counterclockwise rotation but only until half of its total turn before removing both the adapter and generator along with the pulley nut and pulley. Start by taking off the nut from the terminal insulator followed by the terminal plate while continuing with the removal of the rear end cover and generator brush holder and ending with the generator plate seal. The generator regulator assembly requires removal of three screws to become detached. You need to begin by unscrewing the four screws of the generator holder with rectifier then detach the generator rectifier end frame by removing the four terminal insulators and nuts before using Special Service Tool 09286-46011. First disconnect the washer followed by the rotor from the drive end frame to remove the generator rotor assembly. Verify the brush length on the generator brush holder assembly with vernier calipers while it should remain between 9.5 to 11.5 mm (0.374 to 0.453 in.) then replace it when it falls below 4.5 mm (0.177 in.). An ohmmeter should be used to test the resistance between terminals F and B and E and F of the generator regulator assembly which should meet standardized specifications. The generator holder with rectifier needs inspection of resistance levels between positive and negative terminals and each rectifier terminal so replacement action is required when outside specified values. The generator rotor assembly should be checked for roughness and wear and slip ring resistance measurements must be between 2.1 to 2.5 Ohm at 20 degrees Celsius (68 degrees Fahrenheit) and replacement should occur if required. The generator rectifier end frame requires inspection for roughness while the coil wire resistance needs to be checked for value below 1 Ohm or 1 MOhm or higher. To repair the 1ZZ-FE engine generator rotor bearing technicians should use Special Service Tools 09820-00021 and 09820-00031 along with Special Service Tool 09285-76010 for installation of the new bearing. Apply Special Service Tools 09950-60010 (09951-00350) and 09950-70010 (09951-07100) to remove and install the generator drive end frame bearing. Install the generator drive end frame to the generator pulley while adding the rotor and washer and finishing with the rectifier end frame through the use of a socket wrench and press secured by nuts and terminal insulators. After installing the generator holder it requires the rectifier and regulator assemblies together with the brush holder assembly and proper torque values must be applied to all parts. Complete the installation of the pulley by hand and close the pulley nut to 39 Nm (400 kgf.cm, 29 ft.lbf) before finishing at 111 Nm (1,125 kgf.cm, 81 ft.lbf) while keeping the pulley free of obstruction.