2002 Lexus LS 430FACTORY OEM SERVICE PROCEDURE

Charging Systems: Generator: Reassembly

  1. Install rotor to drive end frame.
    1. Place the drive end frame on the pulley.
    2. Install the rotor to the drive end frame.
      Fig 1: Installing Rotor To Drive End
      G01146902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Install coil assembly.
    1. Place the generator washer on the rotor.
      Fig 2: Placing Generator Washer On Rotor
      G01146903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 29 mm socket wrench and press, slowly press in the coil assembly.
      Fig 3: Pressing In Coil Assembly
      G01146904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the coil assembly with the 4 bolts.

      Torque  : 5.8 N.m (59 kgf.cm, 51 in.lbf)

      Fig 4: Locating Coil Assembly Bolts
      G01146905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Install pulley.
    1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
    2. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.

      SST 09820-63011

      Torque  : 39 N.m (400 kgf.cm, 29 ft.lbf)

    3. Check that SST (A) is secured to the pulley shaft.
      Fig 5: Tightening Pulley Nut By Hand
      G01146906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mount SST (C) in a vise.
    5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
      Fig 6: Mounting SST in Vise
      G01146907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.

      Torque  : 110.5 N.m (1,125 kgf.cm, 81 ft.lbf)

    7. Remove the generator from SST (C).
      Fig 7: Turning SST In Proper Direction
      G01146908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Turn SST (B), and remove SST (A and B).
      Fig 8: Removing SST A & B
      G01146909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Install brush holder.
    1. Place the front seal plate to the coil assembly.
      Fig 9: Placing Front Seal Plate To Coil Assembly
      G01146910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the brush holder on the coil assembly.
      NOTE: Be careful of the holder installation direction.
    3. Install the 2 screws.

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

    4. Place the real seal plate on the brush holder.
      Fig 10: Placing Brush Holder To Coil Assembly
      G01146911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Install rear end cover.
    1. Install the terminal insulator.
    2. Install the end cover with the 3 nuts.

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

      Fig 11: Identifying Rear End Cover Nuts
      G01146912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Check that rotor rotates smoothly.
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