Installation Procedure for 7PK Alternator Pulley of Toyota RAV4 1AZFE/2AZFE Engines

I. Pre-installation Preparation

Tools and Materials

• Special tools: SST 09249-63010 (special tool for belt tensioner), SST 09950-60010 (pulley holding sleeve), torque wrench (accuracy ±3%), hex socket (matching the rotor shaft), cleaning cloths, non-corrosive cleaning agent, new 7PK belt (original equipment specification), thread locker (if the nut is not pre-applied with it).

• Safety equipment: Safety goggles, gloves, anti-slip mats, wheel chocks.

Safety and Environment

• Park the vehicle on a flat surface, engage the parking brake, shift to P/N gear, disconnect the negative battery cable (wait for ≥90 seconds to prevent accidental airbag deployment), and remove the engine upper guard plate, right-side fender liner and belt guard.

Component Inspection

• Check that the rotor shaft splines are free of damage, the pulley groove surface has no wear or cracks, the tensioner and idler pulley rotate smoothly without jamming, and confirm that the new belt is of 7PK type with no packaging damage.

II. Installation Steps (Including Belt Reset)

Cleaning and Positioning

• Wipe the rotor shaft end face, splines and pulley inner bore with cleaning agent, blow dry to ensure no oil stains or iron filings remain; align the pulley splines with the rotor shaft, push it manually until it fits against the bearing inner ring, do not strike the pulley.

Pulley Fastening (Key Torque Requirement)

• Install the special sleeve SST 09950-60010 to hold the pulley, insert the hex socket to lock the rotor shaft; use a torque wrench to fasten the nut to 73±12 N·m (original factory specification). It is recommended to increase the torque in 2-3 steps to avoid shaft deformation.

• If it is an overrunning alternator pulley (OAP), confirm the installation direction (the arrow on the pulley faces the outer side of the engine). Never use an air impact wrench to prevent damage to the internal clutch.

Belt Installation (7PK Reset)

• Hook the hexagonal part of the tensioner with SST 09249-63010, rotate it clockwise slowly for ≥3 seconds to release tension, and fit the 7PK belt onto the crankshaft pulley, idler pulley, alternator pulley and tensioner pulley in sequence according to the original routing direction.

• Release the tensioner slowly to ensure the belt is fully seated in all pulley grooves without misalignment or twisting.

Tension Verification

• Press the middle position of the belt (midpoint between two pulleys). The deflection of a new belt shall be 5-7 mm, and that of a used belt (service life ≤5000 km) shall be 7-9 mm. Alternatively, use a tension gauge for measurement. Original factory tension specification for 1AZFE/2AZFE engines: 800-1000 N for new belts, ≥600 N for used belts.

III. Post-installation Inspection and Test Run

Static Inspection

• Visually confirm that the belt is aligned with all pulley grooves without edge protrusion; check that the pulley nut is not loose, and the tensioner returns to the normal position without abnormal noise.

Dynamic Testing

• Reconnect the negative battery cable, start the engine and run at idle speed for 5 minutes, listen for any belt slipping or friction noise; accelerate to 2000 rpm and maintain for 30 seconds, observe that the belt has no fluttering, and the charging voltage is stable at 13.5-14.8 V.

Recheck and Documentation

• After stopping the engine, recheck the pulley nut torque with a torque wrench to confirm no torque loss; record the installation date, vehicle mileage and belt model. It is recommended to inspect the belt every 20,000 km.

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Precautions for Installing the 7PK Alternator Pulley of Toyota RAV4 1AZFE/2AZFE Engines

I. Safe Operation Precautions

Electrical Safety

1. Disconnect the negative battery cable before installation and wait for ≥90 seconds before proceeding with any operation, to prevent accidental deployment of the airbag system or short circuit of the alternator stator windings.

2. Do not pry the pulley or tensioner while the battery is connected, to avoid short-circuiting electrical components with metal tools.

Mechanical Protection

1. Wear safety goggles and non-slip gloves to prevent injury from tool rebound if the pulley nut loosens unexpectedly. Secure the vehicle’s tires with wheel chocks to avoid rolling.

2. Do not use excessive force to pry when removing or installing the belt guard, to prevent the guard from deforming and causing friction noise with the belt during operation.

II. Component Assembly Precautions

Pulley Positioning and Fastening

1. For the overrunning alternator pulley (OAP), strictly follow the installation direction: the arrow on the pulley surface must face the outer side of the engine. Reversed installation will lock the one-way clutch and cause the alternator to fail to generate electricity normally.

2. When fastening the nut, use the special sleeve SST 09950-60010 to hold the pulley in place, and insert a hex socket to lock the rotor shaft at the same time. Never directly tighten the nut, otherwise the rotor shaft splines may break.

3. Tighten the nut strictly according to the torque specification of 73±12 N·m, and increase the torque in 2–3 steps (pre-tighten to 30 N·m first, then to 50 N·m, and finally to the standard value). Do not use an air impact wrench, to prevent damage to the internal structure of the OAP.

4. If the nut is not pre-coated with thread locker, apply Toyota genuine thread locker (model: 08833-00080) only on the lower half of the nut threads. Avoid getting the thread locker into the bearing, as this may cause jamming.

7PK Belt Installation Requirements

1. Install the belt strictly following the original routing direction, which can be referenced from the belt routing label in the engine compartment. Incorrect routing will cause the alternator to rotate in reverse, lead to charging system failure, and even cause belt tooth skipping or breakage.

2. Ensure the belt fits fully into all pulley grooves with no edges protruding outside the grooves. Release the tensioner slowly (taking ≥3 seconds) to avoid excessive instantaneous stress on the belt.

3. Do not mix new and used belts. It is recommended to replace the belt, tensioner and idler pulley in the same drive system simultaneously, to prevent belt slipping caused by inconsistent wear between new and old components.

Cleaning and Protection

1. Wipe the rotor shaft splines and pulley inner bore thoroughly with a non-corrosive cleaning agent, then blow dry to ensure no oil stains or iron filings remain. Residues will result in improper pulley installation and axial movement during operation.

2. Do not strike the end face of the pulley during installation, to prevent bearing damage. After assembly, confirm that the pulley rotates smoothly without jamming or abnormal noise.

III. Post-installation Verification Precautions

Static Inspection

1. Visually confirm that the belt is fully engaged with the crankshaft pulley, idler pulley and alternator pulley, with no twisting or misalignment. Check that the pulley nut is tight and the tensioner pointer is within the normal scale range.

2. Recheck the pulley nut torque to confirm no torque loss, to prevent the nut from loosening due to thermal expansion and contraction of metal components after engine warm-up.

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References：

I. Core Technical Documents (with Chapters/Numbers)

II. Sources of SST Tools and Parameters

1. SST 09950-60010: Pulley holding sleeve, sourced from the Special Tools List of 1AZFE/2AZFE Engines (Appendix of RM916E).

2. SST 09249-63010: Special tool for tensioner, derived from the operation instructions of "Drive Belt Replacement" in Chapter 14 of the RAV4 XA30 Repair Manual.

3. Torque and tension standards: The tension of new belts (800–1000 N) and deflection (5–7 mm) are sourced from the Technical Parameter Table of Toyota Engine Accessory Drive System (EM-14-202).

III. Retrieval and Verification Methods

1. Access the Toyota Technical Information System (TIS), and input the Vehicle Identification Number (VIN) to query the corresponding RM manual version (e.g., RM916E/RM864E).

2. The compatibility of the 7PK belt corresponding to the part number 90916-02508 can be verified via the Toyota Electronic Parts Catalog (EPC).

3. The model and usage method of SST tools can be retrieved in the "Special Tools" chapter of the repair manual or the TIS tool database.