2005 Lexus LX 470FACTORY OEM SERVICE PROCEDURE

Charging Systems: Charging: Generator: Reassembly

  1. INSTALL GENERATOR ROTOR 
    1. Place the drive end frame on the pulley.
    2. Install the rotor to the drive end frame.
    3. Install the generator washer.
    Fig 1: Installing Generator Rotor
    G02985084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL RECTIFIER END FRAME 
    1. Using a 21 mm deep socket wrench and press, carefully press in the rectifier end frame.
      Fig 2: Installing Rectifier End Frame
      G02985085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the 4 bolts.

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

    Fig 3: Identifying Rectifier End Frame Bolts
    G02985086Courtesy 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 09820-6301 1

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

    3. Check that SST (A) is secured to the pulley shaft.
      Fig 4: Installing Pulley Using SST
      G02985087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mount SST (C) in a vise.
    5. Insert SST (B) into SST (C) to attach the pulley nut to SST (C).
      Fig 5: Inserting SST (B) Into SST (C)
      G02985088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the pulley nut by turning SST (A) in the direction shown in the illustration.

      Torque: 110.3 N.m (1,125 kgf.cm, 81 ft.lbf) 

    7. Remove the generator from SST (C).
      Fig 6: Tightening Pulley Nut By Turning SST (A)
      G02985089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Turn SST (B) and remove SST (A and B).
      Fig 7: Turning SST (B)
      G02985090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Place the brush holder on the rectifier end frame with the pin facing upward.
    10. Install the 2 screws.

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

    Fig 8: Placing Brush Holder On Rectifier End Frame With Pin Facing Upward
    G02985091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL REAR END COVER 
    1. Install the terminal insulator.
      NOTE: Be careful of the insulator's installation direction.
Factory Service Tools

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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.