OEM 2008 Toyota Sienna Alternator

2008 Toyota Sienna Parts Questions & Experts Answers

• Q: How to reassemble the alternator on 2008 Toyota Sienna?

  A: The first step of alternator reassembly requires placing the drive end frame on the clutch pulley followed by installation of the generator rotor assembly onto the drive end frame. A new generator washer needs placement on the generator rotor. After preparing the generator coil assembly with a press and deep socket wrench (21 mm) insert it slowly before securing the 4 bolts that necessitate 5.8 Nm (59 kgf-cm, 51 in-lbf) torque settings. After inserting 2 brushes into the brush holder it should be attached to the generator coil through 2 screws which require 1.8 Nm (18 kgf-cm, 16 in-lbf) torque settings but the dia1.0 mm (0.039 in.) pin must be left in place before and after this operation. Place the generator coil terminal insulator in its proper direction after which you should mount the generator rear end cover to the generator coil with 3 nuts driven to 4.6 Nm (47 kgf-cm, 41 in-lbf). Fix the clutch pulley temporarily onto the rotor shaft followed by using the Rotor Shaft Holding Tool (Special Service Tool: 09820-63020) and Clutch Pulley Wrench to clamp the tool onto a vise with the shaft inserted. The Clutch Pulley Wrench needs to fit onto the clutch pulley for clockwise tightening using a torque wrench with 110 Nm (1125 kgf-cm, 81 ft-lbf) without the Special Service Tool or a torque of 84 Nm (857 kgf-cm, 62 ft-lbf) with it, with a wrench fulcrum length of 318 mm (12.52 in.) while maintaining the wrench tool parallel to the cycle. Squeeze the generator assembly before taking it out of the Special Service Tool to examine the smooth rotation of the clutch pulley and then apply a new clutch pulley cap onto the clutch pulley.