2005 Lexus IS 300 Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Charging Systems: Charging: Generator: Reassembly

  1. PLACE DRIVE END FRAME ON PULLEY 
    2. Fig 1: Placing Drive End Frame On Pulley
    G02947150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL ROTOR TO DRIVE END FRAME 
  3. INSTALL RECTIFIER END FRAME 
    1. Place the generator washer on the rotor.
      Fig 2: Placing Generator Washer On Rotor
      G02947151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
      Fig 3: Pressing In Rectifier End Frame
      G02947152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 nuts.
      1. Torque: 4.5 N.m (46 kgf.cm, 48 in.lbf) 
    4. Install the wire clip with the nut.
      1. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 
      Fig 4: Installing Wire Clip With Nut
      G02947153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. 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.
      1. SST 09820-6301 1
      2. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
      Fig 5: Tightening SST Clockwise
      G02947154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that SST (A) is secured to the pulley shaft.
    4. Mount SST (C) in a vise.
      Fig 6: Mounting SST In Vise
      G02947155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
    6. To torque the pulley nut, turn SST (A) in the direction shown in Fig 7 .
      1. Torque: 110.5 N.m (1,125 kgf.cm, 81 ft.lbf) 
      Fig 7: Turning SST To Tighten Pulley Nut
      G02947156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the generator from SST (C).
    8. Turn SST (B), and remove SST (A and B).
  5. INSTALL RECTIFIER HOLDER 
    1. Install the 4 rubber insulators on the lead wires.
      Fig 8: Installing Rubber Insulators On Lead Wires
      G02947157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rectifier holder while pushing it with the 4 screws.
      1. Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf) 
      Fig 9: Installing Rectifier Holder
      G02947158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER 
    1. Place the seal plate on the rectifier end frame.
      Fig 10: Placing Seal Plate On Rectifier End Frame
      G02947159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the voltage regulator and brush holder on the rectifier end frame.
      NOTE: Be careful of the holder installation direction. 
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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.