OEM 2005 Toyota MR2 Spyder Alternator

2005 Toyota MR2 Spyder Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2005 Toyota MR2 Spyder?

  A: Start servicing the alternator by first removing the rear end cover through the process of removing the nut and terminal insulator and then the bolt and three nuts and plate terminal and end cover. The procedure starts with unmounting the voltage regulator along with brush holder by removing the brush holder cover then unscrewing five screws and removing the brush holder while taking off the voltage regulator next to separate the seal plate from the rectifier end frame. Begin service of the rectifier holder by removing its screws along with four rubber insulators. Special Service Tool 09820-63010 should be used with a torque wrench to secure the pulley with the socket positioned clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf) while connecting the tool to the rotor shaft before mounting the adapter into a vise and inserting the socket to attach the pulley nut to the adapter. Adjust the pulley nut using a counterclockwise motion from Special Service Tool 09820-63010 although maintain less than half a turn to protect the rotor shaft and then remove the generator along with the adapter and pulley components. Special Service Tool 09286-46011 allows you to remove the generator washer when you detach the rectifier end frame through four nuts and a wire clip. Use an ohmmeter to check the F-to-B and F-to-E terminal continuity of the voltage regulator for inspection purposes until you confirm the recommended standards for replacement. The slip rings of the rotor must show between 2.1 to 2.5 ohms resistance at 20 degrees Celsius while never showing any connection between the slip rings and rotor. A radius measurement of the slip rings should be conducted to determine if replacement of the rotor is needed. The standard size range for slip rings is 14.2 - 14.4 mm with a minimum requirement of 12.8 mm. Open circuit evaluation and ground tests should be performed on the stator device with replacement of the drive end frame assembly when no continuity is found. Observe the brush holder assembly length as it should be between 9.5 - 11.5 mm and replace the assembly when below 1.5 mm. Use an ohmmeter to check rectifier continuity before replacing the holder at any time the test results show inadequate continuity. Worn bearings should be replaced during this inspection process. The procedure starts from the front bearing by unscrewing four bolts and removing the bearing retainer before using Special Service Tool 09950-60010 (09951-00350), 09950-70010 (09951-07100) to press the old bearing out and install a new one which requires the same tools while reinstalling with four bolts at 3.0 N.m (31 kgf.cm, 27 in.lbf). Remove the rear bearing cover and bearing through the use of Special Service Tool 09820-00021 while avoiding fan damage and press a new bearing with Tool 09820-00030 and push in the outer bearing cover with Tool 09285-76010. Attach the rotor to the drive end frame followed by applying the generator washer to the rotor then use a 29 mm socket wrench to press in the rectifier end frame which requires wire clip alongside four nuts (Nut A: 4.5 N.m and Nut B: 5.4 N.m) for securing. Lock the pulley with the hand until achieved, then apply torque to 39 N.m (400 kg.cm, 29 ft.lb) using the pulley holding tool followed by final torque of 111 N.m (1,132 kg.cm, 82 ft.lb). The rectifier holder requires four rubber insulators to be installed in the right direction before securing it with four screws set to 2.9 N.m (30 kgf.cm, 26 in.lbf). Place the seal plate alongside the voltage regulator and the brush holder onto the rectifier end frame before securing them with five screws at 2.0 N.m (20 kgf.cm, 18 in.lbf) tighten them and cover the brush holder. Afterward place the end cover alongside plate terminal and bolt it to three nuts (Nut: 4.4 N.m and Bolt: 3.9 N.m) before attaching the terminal insulator using a nut at 4.1 N.m (42 kgf.cm, 36 in.lbf) to ensure the rotor has smooth rotation.