In the article, we will consider disassembly, assembly and verification of generator parts

We remove the generator from the car, as described in the previous article

Toyota Camry alternator repair

Unscrew the pulley fastening nut, holding the generator shaft with the second key and remove the pulley from the shaft

Toyota Camry alternator repair

A pulley with a freewheel can be installed on the generator.

To remove such a pulley, you will need a special tool

Toyota Camry alternator repair

Toyota Camry alternator repair

We unscrew the three nuts securing the brush holder cover and remove the cover

Toyota Camry alternator repair

Remove the insulating sleeve of the generator power contact

Toyota Camry alternator repair

Toyota Camry alternator repair

We unscrew the screw securing the bracket for the harness holder and remove the bracket

Toyota Camry alternator repair

Toyota Camry alternator repair

We unscrew the two screws securing the brush holder and remove it

Toyota Camry alternator repair

We unscrew the four coupling bolts of the generator

Toyota Camry alternator repair

Toyota Camry alternator repair

Install the screw puller and separate the stator from the cover on the drive side

Toyota Camry alternator repair

In order not to damage the rotor shaft, we substitute a suitable socket head under the puller screw

Toyota Camry alternator repair

Remove the spring ring and drive side cover from the rotor shaft

Toyota Camry alternator repair

Inspecting the cover of the generator.

Toyota Camry alternator repair

If during rotation and the bearing, there is a play between the rings, rolling or jamming of the rolling elements, protective rings are damaged or there are traces of grease leakage, replace the bearing.

If cracks are found on the cover, especially in the places where the generator is attached, it is necessary to replace the cover

Toyota Camry alternator repair

Toyota Camry alternator repair

To replace the front rotor bearing, unscrew the four screws securing the pressure plate and remove the plate

Toyota Camry alternator repair

Press the bearing out of the cover

Toyota Camry alternator repair

We press the new bearing into the cover with a mandrel of a suitable size, applying force to the outer ring

Check the ease of rotation of the bearing from the side of the slip rings.

If during the rotation of the bearing there is play between the rings, rolling or jamming of the rolling elements, the protective rings are damaged or there are traces of lubricant leakage, the rotor assembly with the bearing should be replaced

Toyota Camry alternator repair

Check the resistance of the rotor winding by connecting the tester to slip rings.

Resistance should be about 2.3-2.7 ohms.

If the tester shows infinity, then there is a break in the windings and the rotor needs to be replaced

Toyota Camry alternator repair

Checking the short circuit of the rotor winding to ground.

To do this, we connect the tester probes to the rotor pole and alternately to the slip rings.

The measured resistance must be infinite, otherwise we replace the rotor

Toyota Camry alternator repair

Measure the diameter of the slip rings of the rotor.

If the diameter of any ring is less than 14 mm, replace the rotor

Toyota Camry alternator repair

Checking the protrusion of the brushes in a free state.

If the brushes protrude less than 4.5 mm, replace the brush holder assembly

Assemble the generator in reverse order

Toyota Camry alternator repair

Before installing the brush holder, we sink its brushes into the holes of the brush holder and insert a rod of a suitable size

Toyota Camry alternator repair

After installing the brush holder, remove the rod

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