OEM 2000 Toyota RAV4 Alternator

2000 Toyota RAV4 Alternator Parts Q&A

• Q: How to service and repair the alternator on 2000 Toyota RAV4?

  A: Start the alternator repair by you should first detach each part: remove the back cover through the nut and terminal insulator before taking off the bolt and 3 nuts then the plate terminal and end cover. The service starts by taking off the seal plate from the rectifier end frame and continuing with removing the brush holder and voltage regulator through steps including the brush holder cover and five screws before getting to the brush holder and voltage regulator respectively. Start by removing the four screws holding the rectifier holder and its subsequent detachment followed by removal of four rubber insulators. The pulley removal process requires Special Service Tool 09820-63010 with a torque wrench to adjust the clockwise socket to 39 Nm (400 kgf.cm, 29 ft.lbf) while coupling the tool to the rotor shaft followed by mounting the adapter in a vise and inserting the socket to attach the pulley nut to the adapter. Use the tool to turn the pulley nut counterclockwise until you reach a half turn only to prevent rotor shaft damage and remove the generator from the adapter along with both pulley nut and pulley. Use Special Service Tool 0928-46011 to detach the rectifier end frame after you remove 4 nuts and wire clip and take out the generator washer from the rotor. For reassembly, place the rectifier end frame on the pulley, install the rotor to the drive end frame, and then install the rectifier end frame by placing the generator washer on the rotor, pressing in the frame with a 29 mm socket wrench, and securing it with the wire clip and 4 nuts, torquing to 4.5 Nm (46 kg.cm, 40 in.lb) for A and 5.4 Nm (55 kg.cm, 48 in.lb) for B. Install the pulley by hand-tightening the nut, then use the pulley holding tool to torque it to 39 N.m (400 kg.cm, 29 ft.lb) and finally to 111 N.m (1,132 kg.cm, 82 ft.lb). Fasten the rectifier holder by securing 4 screws into place with the correct installation direction while torquing them to 2.9 Nm (30 kg.cm, 26 in.lb). Secure the seal plate onto the rectifier end frame before placing the voltage regulator and brush holder with proper installation direction and use 5 screws torqued to 2.0 Nm (20 kg.cm, 18 in.lb) then cover the brush holder. The end cover installation requires a bolt combined with 3 nuts to connect the end cover and plate terminal while torquing the nut to 4.4 Nm (45 kg.cm, 39 in.lb) and the bolt to 3.9 Nm (39 kg.cm, 35 in.lb) and torquing the terminal insulator with the nut at 4.1 Nm (42 kg.cm, 36 in.lb). Confirm that rotor movement remains consistent during its rotation.