2001 Lexus ES 300FACTORY OEM SERVICE PROCEDURE

Charging Systems: Disassembly

  1. Remove rear end cover. 
    1. Remove the nut and terminal insulator.
    2. Remove the screw, 3 nuts, plate terminal and end cover.
    Fig 1: Removing Generator Rear End Cover
    G03138861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove brush holder and voltage regulator. 
    1. Remove the brush holder cover from the brush holder.
    2. Remove the 5 screws, brush holder and voltage regulator.
    Fig 2: Removing Brush Holder & Voltage Regulator
    G03138862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Remove rectifier holder. 
    1. Remove the 4 screws and rectifier holder.
    2. Remove the 4 rubber insulators.
    3. Remove the seal plate.
    Fig 3: Removing Rectifier Holder
    G03138863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Remove pulley. 
    1. Hold SST (SST 09820-63010-A) with a torque wrench, and tighten SST (SST 09820-63010-B) clockwise to the specified torque.
      1. Torque:  39 N.m (400 kgf.cm, 29 ft. lbf)
    2. Check that SST (SST 09820-63010-A) is secured to the rotor shaft.
      Fig 4: Securing SST 09820-63010-A To Generator Rotor Shaft
      G03138864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mount SST (SST 09820-63010-C) in a vise.
    4. Insert SST (SST 09820-63010-B) into SST (SST 09820-63010-C), and attach the pulley nut to SST (SST 09820-63010-C).
      Fig 5: Mounting SST 09820-63010-C In Vise
      G03138865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. To loosen the pulley nut, turn SST (SST 09820-63010-A) in the direction shown. See Fig 6.
      NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
    6. Remove the generator from SST (SST 09820-63010-C).
      Fig 6: Loosening Generator Pulley Nut
      G03138866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Turn SST (SST 09820-63010-B), and remove SST (SST 09820-63010-A and SST 09820-63010-B).
    8. Remove the pulley nut and pulley.
    Fig 7: Removing Generator Pulley
    G03138867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove rectifier end frame. 
    1. Remove the 4 nuts and cord clip.
      Fig 8: Identifying Rectifier End Frame Nuts & Cord Clip
      G03138868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST (SST 09286-46011), remove the rectifier end frame.
    3. Remove the generator washer.
    Fig 9: Removing Rectifier End Frame
    G03138869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Remove rotor from drive end frame. 
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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