OEM 2006 Toyota Camry Alternator

2006 Toyota Camry Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2006 Toyota Camry?

  A: The procedure for alternator repair begins with pulley removal through the use of Special Service Tool 09820-63010 (09820-06010, 09820-06020) by applying torque pressure created by a torque wrench to secure the pulley holding tool on the rotor shaft to 39 Nm (400 kgf.cm, 29 ft.lbf). After securing the tool apply the adapter to a vise clamp before putting the socket into place along with the pulley nut. After applying counterclockwise torque to the holding tool you must stop before reaching the half turn threshold to protect the rotor shaft. First remove the generator from the adapter and after that take off the socket and pulley holding tool before removing the pulley nut and pulley. Set the generator onto the generator pulley before removing three nuts which will expose the rear end cover. The generator brush holder assembly requires screw removal of its two screws to expose the terminal insulator on the generator rectifier end frame. Use Special Service Tool 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) to remove the generator rectifier end frame after you take out the four bolts from the generator coil assembly. The next step requires removal of the generator washer together with the rotor assembly. A vernier caliper must be used to measure the brush length of the generator brush holder assembly. The brush length should be between 4.5 to 10.5 millimeters (0.177 to 0.413 inches). An ohmmeter should be used to measure resistance in the generator rotor assembly while checking for proper bearing health and slip ring condition as well as open circuit and ground testing to verify the standards of 2.3 to 2.7 Ohm at 20 degrees Celsius (68 degrees Fahrenheit) and 10 k Ohm or higher for ground. Thoroughly examine the slip ring diameter since it should fall within 14.0 to 14.4 mm (0.551 to 0.567 inches). The generator drive end frame bearing requires first wear inspection before removal through four screw undoing followed by installation with Special Service Tools 09950-60010 (09951-00250) and 09950-70010 (09951-07100) using a tapping system. Clamp in the new bearing through the same tooling process before fixing the retainer plate onto the unit by tightening its screws to 2.3 Nm (23 kgf.cm, 20 in.lbf). Afterward the generator drive end frame should be positioned onto the generator pulley and the generator rotor and washer should be added followed by gradual press fitting of the generator rectifier end frame which requires four bolts tightened to 5.8 Nm (59 kgf.cm, 51 in.lbf). Decrease the brush holder pins to 1.0mm (0.039in) while pushing the brushes inward before screwing two bolts to 1.8Nm (18kgf.cm, 16in.lbf). Remove the pins after screw installation. The terminal insulator needs correct orientation before being attached to the generator rectifier end frame which requires installation of the rear end cover using three nuts tightened to 4.6 Nm (47 kgf.cm, 41 in.lbf). Finish the generator pulley installation with Special Service Tool 09820-63010 (09820-06010, 09820-06020) by first tightening the pulley nut manually then locking it with the holding tool and torque wrench to 39 Nm (400 kgf.cm, 29 ft.lbf), placing the adapter in a vise before finishing nut tightening to 111 Nm (1,125 kgf.cm, 81 ft.lbf) while verifying the pulley moves easily.