Reassembly [12/2013 - 11/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Highlander, 2015 Toyota Highlander, and 2014 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL GENERATOR DRIVE END FRAME BEARING

Using SST and a press, install a new generator drive end frame bearing.

SST: 09950-60010
1. 09951-00470
SST: 09950-70010
1. 09951-07100

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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
1. Place the generator drive end frame on the generator pulley with clutch.
2. Install the generator rotor assembly to the generator drive end frame.

INSTALL GENERATOR PULLEY WITH CLUTCH

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

Place the rotor shaft end into SST (A).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Rotor Shaft

SST: 09820-63021

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

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Hold
*b	Turn
*c	Length of SST 100 mm (3.94 in.)
*d	Length of Torque Wrench 400 mm (1.31 ft.)

without SST [Torque (N*m(kgf*cm, ft.*lbf))]

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

with SST [Reading of Torque wrench (N*m(kgf*cm, ft.*lbf))]

Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)

HINT:

The "with SST" torque value is effective when SST is parallel to the torque wrench.
The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.).
The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 400 mm (1.31 ft.).
If using a torque wrench with a different length, or connecting the torque wrench and SST at an angle, refer to the alternate torque values.
Refer to PRECAUTION [12/2013 - 11/2016]

Remove SST from the generator pulley with clutch.
Check that the generator pulley with clutch rotates smoothly.

INSTALL GENERATOR COIL ASSEMBLY

Place a new washer on the generator rotor assembly.

Using a 21 mm socket wrench and press, slowly press the generator coil assembly to install it.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	21 mm Socket Wrench

Install the 4 bolts.
Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)

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.

*a	Pin (1.0 mm)

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

*a	Pin (1.0 mm)

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

Install the generator terminal insulator to the generator coil assembly.

NOTE:

Be sure to install the generator terminal insulator in the correct direction.

INSTALL GENERATOR REAR END COVER
1. Install the generator rear end cover to the generator coil assembly with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
INSTALL GENERATOR PULLEY CAP
1. Install a new generator pulley cap to the generator pulley with clutch.