OEM 2005 Toyota Solara Alternator

2005 Toyota Solara Parts Questions & Experts Answers

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

  A: The first step to service an alternator requires the usage of Special Service Tool 09820-63010 (09820-06010, 09820-06020). Secure the holding tool onto the rotor shaft using a torque wrench set to 39 Nm (400 kgf.cm, 29 ft.lbf). First secure the tool before clamping the adapter into a vise while inserting the socket next to it and attaching the pulley nut. Turn the holding tool counterclockwise while keeping an eye on the rotor shaft to prevent damage but do not pass halfway to damage the shaft. Start by taking the generator off the adapter and proceed to detach both the socket and pulley holding tool followed by the removal of the pulley nut and pulley. Set the generator on the generator pulley before you remove the three nuts and place the rear end cover aside. Remove the terminal insulator from the generator rectifier end frame before unfastening the two screws to remove the generator brush holder assembly. Using Special Service Tool 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) you can detach the generator rectifier end frame by removing its four bolts. Proceed to take away the generator washer and rotor assembly. Use a vernier caliper to measure the brush length on the generator brush holder assembly before making a replacement when measurement results show less than 4.5 mm. The assessment of rotor assembly includes bearing condition inspection as well as measurements to check open circuits with slip rings (2.3 to 2.7 ohm at 20 degrees Celsius) and ground performance by evaluating slip ring to rotor core resistance (10 k ohm or higher). Rotor slip rings should be checked for roughness and scoring. A rotor assembly should be replaced when the slip ring diameter becomes smaller than 14.0 mm. The generator drive end frame bearing should be inspected for wear and taping can begin by unscrewing four screws, utilizing Special Service Tool 09950-60010 (09951-00250) and 09950-70010 (09951-07100) to remove the bearing. The installation of a new bearing requires Special Service Tools 09950-60010 (09951-00470) and 09950-70010 (09951-07100) while using a press before securing the retainer with four screws tightened to 2.3 Nm (23 kgf.cm, 20 in.lbf). Place the generator pulley onto the drive end frame and follow it with the rotor assembly and washer. Apply a 21 mm deep socket wrench to press in the generator rectifier end frame before tightening four bolts to 5.8 Nm (59 kgf.cm, 51 in.lbf). First install the two brushes into the holder followed by a 1.0 mm pin; secure them with two screws at 1.8 Nm (18 kgf.cm, 16 in.lbf) before removing the pin. Install the terminal insulator properly to the generator rectifier frame while orienting it correctly before securing the rear end cover with three nuts at 4.6 Nm (47 kgf.cm, 41 in.lbf). The generator pulley maintenance requires hand-tightening of the pulley nut before securing it with a holding tool while torque-wrenching to reach 39 Nm (400 kgf.cm, 29 ft.lbf) using Special Service Tool 09820-63010 (09820-06010, 09820-06020). Use a vise to clamp the adapter before adding the socket and pulley nut then tighten it to 111 Nm (1,125 kgf.cm, 81 ft.lbf). After that remove the generator from the adapter while taking out the holding tool and socket then make sure the pulley operates without resistance.