Reassembly [08/2020 - ]: Procedure

WARNING: This page is about a different car, the 2024 Lexus ES 250, 2023 Lexus ES 250, 2022 Lexus ES 250, and 2021 Lexus ES 250. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL GENERATOR ROTOR BEARING

Using SST and a press, install a new generator rotor bearing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09950-60011
1. 09951-00470
SST: 09950-70010
1. 09951-07100

Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Tab
*b	Cutout

Install the 4 screws.
Torque: 2.3 N.m (23 kgf/cm, 20 in.lbf)

INSTALL GENERATOR ROTOR ASSEMBLY

Place the generator drive end frame on the generator pulley with clutch.

Install the generator rotor assembly to the generator drive end frame.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Generator Rotor Assembly
*2	Generator Drive End Frame

INSTALL GENERATOR COIL ASSEMBLY

Place a new washer on the generator rotor assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a 21 mm deep socket wrench and press, slowly press in the generator coil assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	21 mm Deep Socket Wrench

Install the 4 bolts.

Torque: 5.9 N.m (60 kgf/cm, 52 in.lbf)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder assembly hole.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Pin (1.0 mm)

Install the generator brush holder assembly to the generator coil assembly with the 2 screws.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Pin (1.0 mm)
	Pull out

Torque: 1.8 N.m (18 kgf/cm, 16 in.lbf)

Pull out the pin from the generator brush holder assembly hole.

INSTALL GENERATOR TERMINAL INSULATOR

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the generator terminal insulator to the generator coil assembly.
  NOTE:
  Be sure to install the generator terminal insulator in the correct orientation.

INSTALL GENERATOR REAR END COVER

Install the generator rear end cover to the generator coil assembly with the 3 nuts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 4.6 N.m (47 kgf/cm, 41 in.lbf)

INSTALL GENERATOR PULLEY WITH CLUTCH

Secure the generator drive end frame in a vise between aluminum plates.
Temporarily install a new generator pulley with clutch to the rotor shaft.

Install SST (A) to SST (B) as shown in the illustration.

SST: 09820-63021

Fit the rotor shaft end into SST (A).

*a	Rotor Shaft

Fit SST (B) to the generator pulley with clutch.

*1	Generator Pulley with Clutch

Tighten the generator pulley with clutch by turning SST (B) as shown in the illustration.

Specified tightening torque

Torque: 80 N.m (816 kgf/cm, 59 ft.lbf)

NOTE:

Check that the generator drive end frame is secured in the vise tightly.
Hold SST (A) tightly during the operation.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Refer to PRECAUTION [06/2018 - ]
When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (1.312 ft.)): 64 N.m (653 kgf/cm, 47 ft.lbf)

*a	Torque Wrench Fulcrum Length
*b	Turn
*c	Hold

Remove SST (A) and (B) from the generator pulley with clutch.
Check that the generator pulley with clutch rotates smoothly.
Remove the generator drive end frame from the vise.

INSTALL GENERATOR PULLEY CAP
1. Install a new generator pulley cap to the generator pulley with clutch.