OEM 2005 Toyota RAV4 Alternator

2005 Toyota RAV4 Alternator Parts Q&A

• Q: How to service and repair the alternator on 2005 Toyota RAV4?

  A: First remove the rear end cover for the alternator of all 12 V 90 A and 100 A types by removing their associated nuts, bolts and terminal insulator. The brush holder and voltage regulator need to be removed from the 12 V 90 A type by extracting screws and seal plate screws while the terminal insulator and screws must be removed from the 12 V 100 A type. When removing the rectifier holder start by unscrewing its four screws and rubber insulators then use Special Service Tool 09820-63011 to remove the pulley but ensure that the socket reaches a torque of 39 Nm (400 kgf.cm, 29 ft.lbf) while avoiding over half-turn looseness of the pulley nut. Use tool 09286-46011 to remove the 12 V 90 A type end frame when its nuts and wire clip have been removed. The 12 V 100 A type requires tool 09950-40011 to remove its end frame with unscrewed bolts and cord clip. Replace the front bearing by taking out the bearing retainer before using Special Service Tool 09950-60010 (09951-00350) to extract the existing bearing which you can replace with Special Service Tool 09950-60010 (09951-00530). Reinstall the bearing retainer with specified torque values. Both bearing replacement procedures for the 12 V 90 A type require the operator to use Special Service Tools 09821-00021 and 09820-00031 along with 09825-76010 to complete removal of components and installation of new parts. The final assembly process includes first placing the rotor onto the drive end frame of both types then adding the rectifier end frame afterward according to proper torque specifications for wire clips and bolts. Screw in the pulley manually but tighten the pulley nut to 39 N.m (398 kg.cm, 29 ft.lb) using Special Service Tool 09820-63011 and finish with a torques up to 111 N.m (1,132 kg.cm, 82 ft.lb). The rectifier holder with rubber insulators and the voltage regulator and brush holder items require installation according to specific installation directions and their respective torque specifications. From the back end, apply the rear end cover to both types while confirming every component is tight and inspecting rotor rotation.