Step by step DIY Alternator Replacement

@nj636 did yours take a crap, or just preventative. Which one did you replace it with?

 

His alternators, including a Denso reman, broke after trackday. He needs a racing alternator.

Additionally, "...a wire that is too small when used on a high output alternator can cause the power to back up within the alternator making it overheat, burn up and fail."
https://alternatorparts.com/do-i-need-a-bigger-battery-wire.html

Here is another great tip, from same website, to a question I asked earlier, "...you do not need to rip out your old wiring when upgrading. You can piggy back a second wire between the alternator and battery." ... "when running the second wire you should fuse it near the battery."

With respect to fusing, "The fuse is just in case the wire gets pinched or shorted out, the fuse will blow instead of the wire burning up. You should use the largest fuse you can for the wire size, fuses are restrictive to current flow. Typically you want the fuse value to equal 80% of the wires load carrying capacity."

 

Ah gotcha, didn't see that. Good to know, just passing along what I've found. I don't like buying things where you can find very easily as many 'buy beware' threads as I found on those. But there's always more to the story as we just learned

 

I used a Denso. The bearing was smoked

Bearing was smoked. I used the

$236 Denso 2100572 Denso 210-0572 Remanufactured Alternator (2100572)

Denso 2100572.

 

So that is a reman?

 

Finally got around to installing the BnR 200 amp alternator. Found it easier to remove the driver-side skirt to pull out the alt. Torque for the two bolts is 32 ft lb. Good thing about BnR is they don't require a core; so, have new brushes to replace on OEM and will keep as a backup. Thanks for the write-up.

 

NIB

 

welcome

 

anyone have an extremely difficult time getting the one long bolt to line back up? I did when I changed my tensioner,,

 

Haha, only a year later!

 

.
The two mounting bolts are the same length. I installed the upper first, then wiggled the alternator until the bottom holes lined up. If you were re-installing the same alternator I can see you having trouble lining up the alt into place because the lower mounting tab on the alt has a sliding nut. Before installing the alt, the nut needs to be pushed out to give you a little breathing room; you only need a mm. I ran out to my old alt and pushed it out before I forget. Took some pics for you. Pushing it out was a PIA; had to use a 1-inch socket with some washers for stability; then threaded a bolt and used my press. Most alts have a sliding nut like this. It closes up when you torque the bolt.

.....

 

Hey man, how’s your 200a alternator holding up? I’m thinking of getting one.

 

@arwinnnsd It is running well. I installed a 160 amp BnR alt in daughter's Corolla and it's doing well also. My only gripe on both is that the voltage settles down at 13.6 volts, give or take .2 depending on ambient temps. I like to see 14 volts. It could be an expected function of a higher amp alt, but the alts are functioning well otherwise. I did replace the brushes in the OEM alt and it is is stored in the garage as a back up.

 

could you throw me a link for which replacement brushes and bearing you used, I think I would like to rebuild my denso as well.

 

One thing to add while the alternator is out - take out the driver's side VVT screen while you're at it and clean it. You can only reach it when the alternator is off, so why not do it (and the other side) while you're in there.

 

@arwinnnsd I ordered from an online dealer - Elmore Toyota. They are about 90 minutes away; thus, shipping fees were minimal and delivery time was quick. It didn't bother me paying state taxes. I did not replace the bearing. I have not seen how much work that would be. I'll look into that.

 

What’s a VVT screen?

 

well done.

 

@Subway4X4
https://www.tacomaworld.com/threads/this-is-why-you-need-to-replace-your-vvt-screens.639996/

@arwinnnsd
You ever get the high output alternator? Mine is still running well. Recently installed HKB's voltage booster to increase voltage output about .5 volts. Recommended for AGM batteries.
https://www.hkbelect.com/product/24...nic-fuse-version-micro-blade-compatible-2005/
https://www.tacomaworld.com/threads/the-northstar-agm-battery-voltage-booster-upgrade.604478/