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Home >> Toyota >> 2019 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 12 (Battery / Charging System (1AR-FE) (Service Information) (Except Hybrid)) >> Generator >> Reassembly [12/2013 - ] >> Procedure

Reassembly [12/2013 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL GENERATOR DRIVE END FRAME BEARING 
    1. 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
      GTY440382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.
      GTY445287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tab
      *b Cutout
    3. Install the 4 screws.

      Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf) 

  2. 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.
    3. Place a new washer on the generator rotor assembly.
  3. INSTALL GENERATOR COIL ASSEMBLY 
    1. Using a 21 mm socket wrench and press, slowly press the generator coil assembly to install it.
      GTY449742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 21 mm Socket Wrench
    2. Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY 
    1. 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.
      GTY434278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin (1.0 mm)
    2. Install the generator brush holder assembly to the generator coil assembly with the 2 screws.
      GTY455340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin (1.0 mm)

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

    3. Pull out the pin from the generator brush holder assembly hole.
  5. INSTALL GENERATOR TERMINAL INSULATOR 
    1. Install the generator terminal insulator to the generator coil assembly.
      GTY310235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

  6. 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) 

  7. INSTALL GENERATOR PULLEY WITH CLUTCH 
    1. Temporarily install the generator pulley with clutch to the rotor shaft.
    2. Secure the generator drive end frame in a vise between aluminum plates.
    3. Place the rotor shaft end into SST (A).
      GTY455489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rotor Shaft
      • SST: 09820-63021 
    4. Fit SST (B) to the generator pulley with clutch.
    5. Tighten the generator pulley with clutch by turning SST (B) as shown in the illustration.
      GTY436603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
      *c Length of SST 100 mm (3.94 in.)
      *d Length of Torque Wrench 255 mm (10.0 in.)

      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: 57 N*m (581 kgf*cm, 42 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 255 mm (10.0 in.).
      • 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] Refer to PRECAUTION [11/2016 - ]

    6. Remove SST from the generator pulley with clutch.
    7. Check that the generator pulley with clutch rotates smoothly.
  8. INSTALL GENERATOR PULLEY CAP 
    1. Install a new generator pulley cap to the generator pulley with clutch.
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