how to remove alternator on Toyota Hilux

Click this ink below to see the video of alternator bracket rebuild:----

http://www.youtube.com/watch?v=B0yE1CZZjpY

Alternator

REMOVAL & INSTALLATION

On some models, the alternator is mounted very low on the engine. On these models, it may be necessary to remove the gravel shield and work from beneath the truck in order to gain access to the alternator. Replacing the alternator while the engine is cold is recommended. A hot engine can result in personal injury.

22R and 22R-E Engines

See Figures 8 and 9

1. Disconnect the negative battery terminal.
2. If the vehicle is equipped with power steering, drain the coolant from the system.

WARNING

Housepets and small animals are attracted to the odor and taste of engine coolant (antifreeze). It is a highly poisonous mixture of chemicals; special care must be taken to protect open containers and spillage.

3. Disconnect the wiring at the back of the alternator. Lift the rubber boot, remove the nut from the external terminal and the wire.

Fig. Fig. 8: Remove the nut and wire from the alternator

4. If equipped with power steering, remove the engine splash shield or undercover, then the water inlet pipe.

Fig. Fig. 9: If your vehicle has power steering, remove the water inlet pipe for ease of access

5. If the truck has air conditioning, remove the No. 2 (lower) fan shroud.
6. Loosen the pivot bolt and remove the adjusting bolt.
7. Push the alternator towards the engine and remove the belt.
8. Hold the alternator; remove the pivot bolt then the alternator.

To install:

9. Mount the alternator on its bracket; install the pivot and adjusting bolts.
10. Install the drive belt and adjust it correctly. Tighten the pivot and adjusting bolts.
11. Install the water inlet hose if it was removed. Install the fan shroud and install the engine splash shield.
12. Connect the wire to the terminal; install the nut and secure the rubber boot. Attach the wire harness connector to the alternator.
13. Close the radiator drain cock and refill the system with coolant.
14. Connect the negative battery cable.

3VZ-E and 3F-E Engines

See Figures 8 and 9

1. Disconnect the negative battery cable.
2. Disconnect the wiring at the back of the alternator. Lift the rubber boot, remove the nut from the external terminal and the wire.
3. Loosen the alternator pivot bolt and loosen the upper locknut.
4. Push the alternator towards the engine and remove the belt.
5. Remove the pivot and adjusting bolts. On 3F-E, remove the nuts and bolts holding the air pump support, then remove the adjusting bar and its bolts.
6. Remove the alternator.

To install:

7. Place the alternator in position and loosely install the pivot and adjusting bolts.
8. On 3F-E, install the adjusting bar and its 2 bolts. Set the nuts and bolts just snug. Install the air pump support.
9. Install the drive belt; adjust it to the proper tension, tightening the adjusting and pivot bolts. Tighten the 3F-E adjuster bar bolts.
10. Connect the wire to the terminal and install the nut. Fit the rubber boot over the terminal. Attach the plastic wire harness connector.
11. Connect the negative battery cable.

2RZ-FE and 3RZ-FE Engines

See Figures 10 and 11

1. Disconnect the negative battery cable.
2. Disconnect the wiring at the back of the alternator. Lift the rubber boot, remove the nut from the external terminal and the wire.

Fig. Fig. 10: Exploded view of the alternator and drive belt on the 2RZ-FE and 3RZ-FE engines

3. Loosen the alternator lockbolt, pivot bolt, nut and adjusting bolt.

Fig. Fig. 11: Locations of the adjusting, pivot and lockbolts

4. Push the alternator towards the engine and remove the belt.
5. Remove the wiring harness with the clip.
6. Remove the alternator lockbolt, pivot bolt, nut.
7. Remove the alternator.

To install:

8. Place the alternator into position and loosely install the pivot and adjusting bolts.
9. Install the drive belt; adjust it to the proper tension. Tighten the lockbolt to 21 ft. lbs. (29 Nm) and the pivot bolt to 43 ft. lbs. (59 Nm).
10. Connect the wire harness with clip.
11. Connect the wire to the terminal. Install the nut and tighten to 7 ft. lbs. (10 Nm). Fit the rubber boot over the terminal. Attach the wire harness connector.
12. Connect the negative battery cable.

5VZ-FE Engine

See Figures 12 and 13

1. Disconnect the negative battery cable.
2. Disconnect the wiring at the back of the alternator. Lift the rubber boot, remove the nut from the external terminal and the wire.

Fig. Fig. 12: Exploded view of the alternator and drive belt on the 5VZ-FE engine

3. Loosen the alternator locknut, pivot bolt, nut and adjusting bolt.

Fig. Fig. 13: Locations of the adjusting and pivot bolts and the locknut

4. Push the alternator towards the engine and remove the belt.
5. Remove the alternator lockbolt, pivot bolt, nut.
6. Remove the alternator.

To install:

7. Place the alternator into position and loosely install the pivot and adjusting bolts.
8. Install the drive belt; adjust it to the proper tension. Tighten the locknut 25 ft. lbs. (33 Nm) and the pivot bolt 38 ft. lbs. (51 Nm).
9. Connect the wire to the terminal and install the nut and tighten. Fit the rubber boot over the terminal. Attach the wire harness connector.
10. Connect the negative battery cable.

1FZ-FE Engine

See Figures 14, 15 and 16

1. Disconnect the negative battery terminal.
2. Remove the battery and tray.
3. Disconnect the power steering reservoir tank.
4. Loosen the lock, pivot and adjusting bolts.
5. Remove the 2 drive belts.
6. Disconnect the wiring at the back of the alternator. Lift the rubber boot, remove the nut from the external terminal and the wire.

Fig. Fig. 14: Exploded view of the 1FZ-FE alternator, battery, belt etc. locations

Fig. Fig. 15: Lock, pivot and adjusting bolt locations

Fig. Fig. 16: The wiring clamp is mounted into the alternator as shown

7. Remove the wire clamp from the alternator.
8. Remove the lockbolt, nut and drive belt adjusting bar.
9. Hold the alternator; remove the pivot bolt then the alternator.

To install:

10. Mount the alternator ion the bracket with the pivot bolt. Do not tighten the bolt yet.
11. Install the drive belt adjusting bar with the bolt and nut. Tighten the bolt to 15 ft. lbs. (21Nm).
12. Temporarily install the lockbolt. Connect the alternator wiring, nut and rubber cap.
13. Connect the wire clamp to the alternator.
14. Install the drive belts.
15. Tighten the pivot bolt to 43 ft. lbs. (59 Nm) and the lockbolt to 15 ft. lbs. (21 Nm).
16. Connect the power steering reservoir tank.
17. Install the battery tray and battery.
18. Start the vehicle and check the alternator operation.

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to Wire a Hilux Alternator follow the procedure :---

Put on protective gloves to prevent your hands from getting dirty, but also to protect you from receiving an electric shock while you disconnect the battery cables. Open the hood of the Hilux.

Isolate the electrical supply from the battery. Use a wrench to remove the negative battery cables from the negative terminal of the battery. Remove the positive battery cable form the negative terminal of the battery. The battery terminals are labeled "+" and "-" while the cables are colored red and black, meaning positive and negative respectively. Move the cables away from the battery so they don't accidentally touch the battery terminals while you wire the Hilux alternator.

Locate the four terminals on the Hilux alternator. They are labeled B (alternator output), S (voltage regulator input), L (dashboard warning system) and IG (ignition system).

Locate the four cables that attach to the Hilux alternator. They are nearby and each one is colored differently. The large red cable attaches to terminal B using a nut and bolt while the smaller cables simply use push-in connectors. Each are different sizes so you can only connect them to the correct terminal.

Use a wrench to undo the nut from the bolt on terminal B. Slide over the eyelet on the end of the large red cable. Screw the nut on the bolt and tighten using the wrench.

Select one of the remaining three wires. Systematically try to push the connector into each terminal starting with terminal S. You can only push it in one terminal so if it doesn't go into terminal S, try terminal L and then terminal IG.

Push one of the two remaining connectors into one of the two remaining terminals. It only goes into one of them. Push the last connector into the last terminal.

Use a wrench to reconnect the positive red battery cable to the positive battery terminal. Reconnect the negative black battery cable to the negative terminal of the battery. Close the hood.

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