Hiace alternator removal

[dogsbreath]

The alternator has died in my sons 98 2.4p hiace.
Things look very tight in there.
Anybody able to indicate what else has to come out to get it out and if it needs to come out the top or bottom?

Cheers

[ol' boy]

So when you removed both seats, the hand brake and metal engine covers.
Where did you get stuck?

[Godzilla]

Just eyeball it.

Firstly get the battery terminal off, belt adjustment loose, belt and plugs/connections off and take a moment to take a look around.

Look for wide areas to pull it though, sometimes you may need to rotate it to get it out, if no space, start looking at whats easy to remove to make room.

Even if you asked a qualified mechanic how to remove it he would not be able to answer till he has looked at it and assessed it as above.

Most mechanics do it this way on the fly, just common sense look and work it out as you go....

[ol' boy]

I remember getting mine out, it was a fiddle, but it does come out.
From memory, it did come out from underneath, although i am really not sure.

two forums that are really helpful are:



This might be handy too:

[mrmacka]

If it has got power steering it is a bitch to get out.You have to remove power steering pump.To do this you have to take the pulley of the pump to remove the bolts from the pump.

[dogsbreath]

If it has got power steering it is a bitch to get out.You have to remove power steering pump.To do this you have to take the pulley of the pump to remove the bolts from the pump.

Also had to remove pump and alternator brackets. I vaguely remember having to remove the pump a few years ago just to get a new alternator belt on it.

[ol' boy]

Just did this job today.

It has to be the worst #$% of a thing known to man!
No wonder dogsbreath posted asking questions
Took all day, just finished now.
Also took a lot of imagination to get the task done.

No wonder there is no YouTube Instructional Video for this, because everyone that achieved it, never wanted to think about it again

[ol' boy]

1989–2004 Toyota HiAce (encompassing the RZH1xx series, with the 2RZ-E engine variant introduced in 1998)

Just did this job again, but a much easier way
There seems to be NO help on the internet for this particular vehicle, not a scrape of help for the 2HZ or 2HZ-E 2.4i Engine.

Process to remove Alternator

I managed to do this without removing the Power Steering pump or the Power Steering Pulley
If you have the right tools, you don't need to do either.

Lift Vehicle, you will need access top and bottom (i just used jack stands)
Lift front seat right back, use a weight to hold seat as far out of the way as you can

1. Loosen Alternator bolts top and bottom
2. undo tension bolt all the way, push Alternator back, remove belt.
3. Completely remove top Alternator bolt and bottom alternator bolt, remove alternator from captive mount.
4. Remove wiring

At this point, the Alternator is free but it is trapped in the engine bay!!!
This is the point you start pulling your hair out.

5. Unbolt Power Steering reservoir , 2 small bolts either side
6. Remove smaller Power Steering line
7. Remove larger Power Steering line
8. Completely remove Power Steering Reservoir and larger hose from vehicle
9. Remove dip stick

Now you have enough space, to use one hand to carefully remove the Alternator out via the top.

It is still a bastard of a job, but at least it is not so bad when you know what steps to take. And what is possible.
Hope this helps some others.
(With my Vehicle, i could not see that removing the Power Steering pump was going to help anyway)

I found nothing on the net about it, and what i did find, was for different models or just wrong advise.


Now to pull an Alternator apart and fit new bearings, gulp.

Alternator

Toyota Part No.: 27060-75150
Denso 27060-75150



eBay:

[lsemmens]

Half ya luck OB, I had a nissan Vanette some years back, I do remember that it was easier to work on the engine with the front seats removed. Come to think of it, IIRC, I think the problem was that the dissy was under the driver's seat.

[ol' boy]

This guy is a bit of a hack, but you'll get the idea.
I used my oven and freezer to get the bearings back in with out using undue force on the alloy covers.
Getting the regulator end bearing off was a real bitch, had to make up a tool to remove it.

[mkhannah]

I can't believe you've done it twice oceanboy!

[ol' boy]

I can't believe you've done it twice oceanboy!

Im not a real fan of it either mate
First time was a belt (actually harder then removing the Alt)
Second time a bearing in the Alt.

Don't worry, the water pump will go now