OEM 2006 Toyota Sienna Alternator

2006 Toyota Sienna Parts Questions & Experts Answers

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

  A: The servicing and repairing process for the alternator requires use of Special Service Tool 09820-63010 (09820-06010, 09820-06020) with its socket-tip tightened through the torque wrench to 39 Nm (400 kgf.cm, 29 ft.lbf) so the tool remains fixed to the rotor shaft. The adapter should be clamped in a vise while the socket goes into the adapter followed by connecting the pulley nut. The pulley nut should be loosened through counterclockwise rotation on the pulley holding tool but users should stop turning before the shaft reaches half the complete turn to prevent rotor shaft damage. Proceed by removing the generator from the adapter and then the socket and pulley holding tool while moving next to the pulley nut before the pulley itself. Set the generator onto the generator pulley before removing its three nuts and the generator rear end cover. The terminal insulator should be removed from the generator rectifier end frame before you detach the generator brush holder by unbolting its two screws. Use Special Service Tool 09950-40011 (including its components 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) to remove four bolts prior to separating the generator rectifier end frame. Access the generator drive end frame bearing to perform tapping operations using Special Service Tool 09950-60010 (09951-00250) coupled with 09950-70010 (09951-07100). You need to remove the generator washer and rotor assembly first followed by taking out the four screws and retainer plate to reach this bearing position. Remove the retainer plate before adding a new bearing using pressing tools Special Service Tool 09950-60010 (09951-00470) and 09950-70010 (09951-07100). Lastly, reinstall the retainer plate with 2.6 N.m (27 kgf.cm, 23 in.lbf) screw torque. The generator drive end frame must be positioned onto the generator pulley before installing the generator rotor together with its washer. A deep socket wrench 21 should be used to carefully press in the generator rectifier end frame while tightening four bolts to 5.8 N.m (59 kgf.cm, 51 in.lbf). Install the brush holder after pushing two brushes inside while utilizing a 1.0 mm (0.039 in.) pin to pierce the brush holder hole. You should tighten the two screws to 1.8 N.m (18 kgf.cm, 16 in.lbf) and remove the pin before proceeding. The terminal insulator should be installed onto the generator rectifier end frame with proper orientation and three nuts should be tightened to 4.6 N.m (47 kgf.cm, 41 in.lbf). To finish assembly install the pulley on the rotor shaft before using Special Service Tool 09820-63010 and its variations to achieve a tightness of 39 Nm (400 kgf.cm, 29 ft.lbf) against the shaft while keeping the tool securely attached to the pulley. Apply the adapter into a vise, insert the socket, and attach the pulley nut by tightening it clockwise up to 111 Nm (1,125 kgf.cm, 81 ft.lbf). Detach the generator from the adapter while slowly turning the socket to remove the pulley holding tool until completion. End with a pulley smoothness check.