This procedure covers the removal and replacement of the alternator on a 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine and front-wheel drive configuration.

Warnings

Tools required

Parts

• Alternator assembly × 1 — 27060-0V090 or equivalent OEM/remanufactured unit rated 120A
• Serpentine belt × 1 — Use OEM specification - inspect and replace if worn

Preparation

1. Park the vehicle on level ground and engage the parking brake
2. Turn the ignition off and remove the key fob from the vehicle
3. Allow the engine to cool completely if recently operated
4. Raise the front of the vehicle and support securely on jack stands
5. Remove the engine under cover using 10mm socket to access components from below

Procedure

1. 1

   Disconnect battery negative terminal
   Using a 10mm socket, loosen the negative battery terminal bolt and remove the cable from the battery post. Secure the cable away from the battery terminal to prevent accidental reconnection. Wait at least 90 seconds before proceeding.
   Torque spec

   Battery Terminal Bolts8 Nm (6 lb-ft)
2. 2

   Remove serpentine belt
   Locate the serpentine belt tensioner on the lower left side of the engine. Using a 17mm socket on a breaker bar, rotate the tensioner clockwise to release tension. Slide the belt off the alternator pulley first, then carefully release the tensioner. Remove the belt from the remaining pulleys and note the routing for reinstallation.
3. 3

   Access alternator from below
   Working from underneath the vehicle, locate the alternator on the lower front of the engine block, driver's side. You may need to remove the splash shield clips for better access. The alternator is positioned below the exhaust manifold.
4. 4

   Disconnect alternator electrical connector
   Locate the white plastic electrical connector on the rear of the alternator. Press the locking tab and pull the connector straight off the alternator. Do not twist or force the connector.
5. 5

   Remove alternator output cable
   Locate the rubber boot covering the B+ terminal nut on the rear of the alternator. Pull back the boot and use a 12mm socket to remove the nut securing the battery output cable. Carefully pull the cable terminal off the stud and secure it away from the alternator.
6. 6

   Remove upper alternator mounting bolt
   Using a 14mm socket with an extension, remove the upper alternator mounting bolt that passes through the adjusting bracket. This bolt is accessed from above the alternator. Keep this bolt separate as it may differ from the lower bolts.
   ⚠The alternator may shift once this bolt is removed. Support the alternator with one hand while removing.
   Torque spec

   Alternator Mounting Bolts50 Nm (37 lb-ft)
7. 7

   Remove lower alternator mounting bolt
   Working from below, use a 14mm socket to remove the lower alternator mounting bolt (pivot bolt). This bolt threads into the engine block and may require penetrating oil if corroded.
   Torque spec

   Alternator Pivot Bolt25 Nm (18 lb-ft)
8. 8

   Remove alternator from vehicle
   Support the alternator and carefully maneuver it downward and out through the bottom of the engine bay. You may need to tilt and rotate the unit to clear surrounding components. The alternator comes out from below on this model.
9. 9

   Install replacement alternator
   Position the new or remanufactured alternator into place from below, aligning the mounting points with the bracket and engine block. Ensure the pulley faces outward and electrical connections are accessible from the rear.
10. 10

    Install alternator mounting bolts
    Install the lower pivot bolt finger-tight first, then install the upper mounting bolt. Once both bolts are started, torque the upper mounting bolt to specification first, then torque the lower pivot bolt to its specified value.
    Torque spec

    Alternator Mounting Bolts50 Nm (37 lb-ft)

    Alternator Pivot Bolt25 Nm (18 lb-ft)
11. 11

    Reconnect alternator electrical connections
    Reconnect the battery output cable to the B+ terminal stud on the rear of the alternator. Install the nut and torque to specification. Slide the rubber boot back over the terminal. Press the white electrical connector onto the alternator until it clicks into place.
12. 12

    Install serpentine belt
    Route the new or inspected serpentine belt around all pulleys except the alternator, following the belt routing diagram on the radiator support. Using the 17mm socket, rotate the tensioner clockwise and slide the belt onto the alternator pulley last. Carefully release the tensioner and verify the belt is seated properly in all pulley grooves.
13. 13

    Reconnect battery and reinstall covers
    Reconnect the negative battery cable to the battery terminal and torque the terminal bolt to specification. Reinstall the engine under cover from below. Lower the vehicle from jack stands.
    Torque spec

    Battery Terminal Bolts8 Nm (6 lb-ft)

Reassembly

1. Ensure all electrical connections are fully seated and locked
2. Verify serpentine belt is properly seated on all pulleys with no twists or misalignment
3. Double-check that all mounting bolts are torqued to specification
4. Confirm no tools or parts are left in the engine bay

Verification

• Start the engine and verify the alternator pulley rotates smoothly without noise or vibration
• Check that the battery warning light on the instrument cluster illuminates briefly at key-on, then extinguishes after engine start
• Using a multimeter, verify charging voltage at the battery terminals is between 13.8-14.8 volts at idle with all accessories off
• Turn on headlights, climate control, and other electrical accessories to verify charging system maintains proper voltage under load
• Visually inspect for any fluid leaks or interference with surrounding components
• Test drive the vehicle and monitor the battery warning light to ensure it does not illuminate during operation

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