OEM 2006 Toyota Corolla Alternator

2006 Toyota Corolla Alternator Parts Q&A

• Q: How to overhaul the alternator on 2006 Toyota Corolla?

  A: Start the alternator overhaul by implementing Special Service Tool 09820-63010 (09820-06010, 09820-06020) to remove the pulley by holding the pulley holding tool with a torque wrench while tightening the socket clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf) until the tool achieves proper rotation on the rotor shaft. Start by securing the adapter into a vise before inserting the socket into it then attaching the pulley nut. After that, tighten the pulley holding tool counterclockwise until the pulley nut shows minimal turn but avoid going past half a turn to prevent rotor shaft damage. First remove the generator from the adapter before taking out the socket and pulley holding tool. Then proceed to remove the pulley nut and pulley. The generator brush holder assembly requires removal by first removing the nut and terminal insulator and next the screw and nut for the terminal plate and subsequently the two nuts for the rear end cover and finally the generator brush cover and two screws for the generator brush holder and finally separating the generator plate seal from the generator rectifier end frame. The generator holder with rectifier can be removed by disassembling the three screws before accessing the four screws leading to its removal. To remove the generator rectifier end frame start by using Special Service Tool 09286-46011 to disconnect the four terminal insulators and the four nuts as well as the generator cord clip. The generator rotor assembly removal process starts with taking off the generator washer followed by removing the generator rotor from the generator drive end frame. The generator brush holder assembly requires inspection with vernier calipers to measure brush length. Standard exposed brush length should measure between 9.5 to 11.5 mm (0.374 to 0.453 in.) otherwise the assembly needs replacement when brush length falls below 4.5 mm (0.177 in.). An ohmmeter should be used to check the generator regulator assembly's resistance measurement between F and B and also between E and F terminals, where replacement will occur if the standard resistance levels are not achieved. The generator holder with rectifier requires inspection for resistance testing between the positive (+) terminal to each rectifier terminal while also testing the negative (-) terminal resistance to each rectifier terminal which leads to generator holder with rectifier replacement if the resistance measurements are not according to specifications. The smooth operation of the generator rotor assembly requires checking for roughness and wear followed by measuring slip ring resistances in addition to slip ring-rotor resistances before replacing the rotor if standard limits are not met. Roughness and wear conditions should be checked in generator drive end frames while measuring resistance between coil wires and coil wire-body connections. The generator drive end frame requires replacement if needed. To replace the rotor bearing for the 1ZZ-FE engine type begin by holding the generator rotor through a vise and employ Special Service Tool 09820-00021 to remove the bearing cover then the bearing and utilize the same tool with Press 09820-00031 to install the new bearing following generator rotor placement on the generator pulley after bearing cover installation using Special Service Tool 09285-76010. Remove and install the generator drive end frame bearing using Special Service Tools 09950-60010 (09951-00350), 09950-70010 (09951-07100) while torquing retainer plate screws to 3.0 N.m (31 kgf.cm, 27 in.lbf). The reassembly starts by fitting the generator drive end frame on the generator pulley then installing the generator rotor before adding the generator washer. A socket wrench 29 combined with a press allows you to install the generator rectifier end frame while you secure it with the generator cord clip and four nuts before torquing nut A to 4.5 N.m (46 kgf.cm, 40 in.lbf) and nut B to 5.4 N.m (55 kgf.cm, 48 in.lbf) and then installing the four terminal insulators. The installation process begins with generator holder rectifier attachment using four screws torqued to 2.9 N.m before moving onto generator regulator assembly screws tightened to 2.0 N.m and then finishing with the generator brush holder assembly which must use the correct generator plate seal while torquing screws to 2.0 N.m before securing the generator rear end cover with two nuts torqued to 4.4 N.m. The installation requires attaching both the terminal plate and insulator while tightening the bolt to 3.9 N.m (40 kgf.cm, 35 in.lbf) and the nut to 4.4 N.m (45 kgf.cm, 39 in.lbf). Then apply a torque of 4.1 N.m (42 kgf.cm, 36 in.lbf) when installing the terminal insulator with its nut. Finally, install the pulley using Special Service Tool 09820-63010 (09820-06010, 09820-06020) by tightening the pulley nut by hand, then using the pulley holding tool with a torque wrench to tighten the socket clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf), ensuring the tool is secured to the pulley shaft, followed by clamping the adapter in a vise, inserting the socket into the adapter, and attaching the pulley nut, tightening the pulley nut and turning the pulley holding tool clockwise to 111 Nm (1,125 kgf.cm, 81 ft.lbf), then removing the generator from the adapter, turning the socket to remove the socket and pulley holding tool, and finally checking that the pulley moves smoothly.