2012 Lexus IS 350CFACTORY OEM SERVICE PROCEDURE

Charging System (Service Information): Generator: Reassembly: Reassembly

  1. INSTALL GENERATOR ROTOR ASSEMBLY 
    1. Place the drive end frame on the clutch pulley.
    2. Install the generator rotor assembly to the drive end frame.
      Fig 1: Location of Generator Rotor Assembly
      GTY145836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place a new generator washer on the generator rotor.
      Fig 2: Location of Generator Washer
      GTY127120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL GENERATOR CLUTCH PULLEY 
    1. Temporarily install the clutch pulley onto the rotor shaft.
    2. Mount the generator drive end frame in a vise tightly.
    3. Confirm SST (A) and (B) shown in the illustration.
      Fig 3: Identifying SST
      GTY271809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 SST (A)
      *2 SST (B)
      • SST: 09820-63021 
    4. Place the rotor shaft end into SST (A).
      Fig 4: View Of Placing Rotor Shaft End Into SST
      GTY263102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Rotor Shaft
      *2 SST (A)
    5. Fit SST (B) to the clutch pulley.
      Fig 5: View Of Fitting SST To Clutch Pulley
      GTY250541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Clutch Pulley
      *2 SST (B)
      *3 SST (A)
    6. Tighten the pulley by turning SST (B) in the direction shown in the illustration.
      Fig 6: View Of Tightening Pulley Turning SST
      GTY284310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 SST (B)
      *2 SST (A)
      *3 Fulcrum Length

      without SST 

      Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 

      with SST 

      Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf) 

      NOTE:
      • Use a torque wrench with a fulcrum length of 260 mm (10.24 in.).
      • This torque value is effective when SST is parallel to the torque wrench.
      • Check that the drive end frame is secured in the vise tightly.
      • Hold SST (A) tightly during the operation.
    7. Remove the generator assembly from SST.
    8. Check that the clutch pulley rotates smoothly.
    9. Install a new generator pulley cap to the clutch pulley.
  3. INSTALL GENERATOR COIL ASSEMBLY 
    1. Using a deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly.
      Fig 7: View Of Pressing Generator Coil Assembly
      GTY268191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Deep Socket Wrench (21 mm)
    2. Install the 4 bolts.
      Fig 8: Location of Generator Coil Assembly Bolts
      GTY146426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.) diameter pin into the brush holder hole.
      Fig 9: Identifying Generator Brush Holder Pin
      GTY250552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pin
    2. Install the brush holder assembly to the generator coil with the 2 screws.
      Fig 10: Identifying Brush Holder Assembly With Screws
      GTY283234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pin

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

    3. Pull out the pin from the generator brush holder.
  5. INSTALL GENERATOR TERMINAL INSULATOR 
    1. Install the terminal insulator to the generator coil.
      Fig 11: Location of Terminal Insulator
      GTY288026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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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.