OEM 2006 Toyota Solara Alternator

2006 Toyota Solara Alternator Parts Q&A

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

  A: Service and repair operations on the alternator start with generator disassembly. Begin the generator service by applying Special Service Tool(1-A) through the torque wrench while twisting Special Service Tool(1-B) clockwise until reaching 39 N.m (400 kgf.cm, 29 ft.lbf) torque then ensure the rotor shaft has Special Service Tool(1-B) properly secured. Position Special Service Tool(2) in a vise before inserting both Special Service Tool(1-A and 1-B) into Special Service Tool(2) and then fitting the pulley nut. Turn Special Service Tool(1-A) by keeping the rotation to a stop just before a half turn to prevent rotor shaft damage during the pulley nut loosening process. Remove the generator from Special Service Tool(2) while rotating Special Service Tool(1-B) to take off Special Service Tool(1-A, B) and pulley nut and generator pulley. The generator should be installed onto the generator pulley before removing its 3 nuts and rear end cover. First detach the terminal insulator from the generator rectifier end frame and then remove the generator brush holder assembly by unfastening its two screws. The procedure to remove the generator rectifier end frame starts by unbolted its 4 bolts and utilizing Special Service Tool09950-40011 to complete the separation. The next step requires removal of generator washer and rotor assembly. The drive end frame bearing requires removal of four screws and retainer before tapping it out using Special Service Tools 09950-60010 and 09950-70010. To assemble the drive end frame use Special Service Tools 09950-60010 and 09950-70010 to press in a new bearing before placing the 4 screws on the retainer at a torque setting of 2.3 N.m (23 kgf.cm, 20 in.lbf). After placing the drive end frame onto the generator pulley and generator rotor comes the addition of the washer. Install the 4 bolts of the generator rectifier end frame with a torque of 5.8 N.m (59 kgf.cm, 51 in.lbf) after carefully pressing in the frame with a 21 mm deep socket wrench. Insert 1.0mm pins through the brush holder holes before tightening the holder with two screws at 1.8 N.m (18 kgf.cm, 16 in.lbf) and afterward removing the pins. Attach the terminal insulator onto the generator rectifier end frame maintaining the right orientation before setting the rear end cover with 3 nuts torqued at 4.6 N.m (47 kgf.cm, 41 in.lbf). To finish installation attach the generator pulley by hand-tightening its pulley nut followed by engaging Special Service Tool(1-A) with a torque wrench then applying clockwise torque to Special Service Tool(1-B) until it reaches 39 N.m (400 kgf.cm, 29 ft.lbf). Pay attention to ensuring the rotor shaft accepts Special Service Tool. The process requires installation of Special Service Tool(2) into a vise followed by inserting Special Service Tool(1-A, B) into Special Service Tool(2) while attaching the pulley nut before tightening Special Service Tool(1-A) using the indicated direction to a torque specification of 110 N.m (1,122 kgf.cm, 81 ft.lbf). Turn Special Service Tool(2) to remove the generator then check that the generator pulley operates smoothly.