Toyota Highlander manuals

Toyota Highlander Service Manual: Overhaul

1. REMOVE GENERATOR PULLEY

REMOVE GENERATOR PULLEY


SST 09820-63010 (09820-06010, 09820-06020)

HINT:

REMOVE GENERATOR PULLEY


(a) Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise to the specified torque.

Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)

NOTICE: Check that SST is secured to the rotor shaft.

REMOVE GENERATOR PULLEY


(b) Mount SST (2) in a vise.

(c) Insert SST (1-A, B) into SST (2), and attach the pulley nut to SST (2).

REMOVE GENERATOR PULLEY


(d) To loosen the pulley nut, turn SST (1-A) in the direction shown in the illustration.

NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half turn.

(e) Remove the generator from SST (2).

REMOVE GENERATOR PULLEY


(f) Turn SST (1-B) and remove SST (1-A, B).

(g) Remove the pulley nut and pulley.

2. REMOVE GENERATOR REAR END COVER

REMOVE GENERATOR REAR END COVER


(a) Place the generator on the pulley.

(b) Remove the 3 nuts and rear end cover.

3. REMOVE TERMINAL INSULATOR

REMOVE TERMINAL INSULATOR


(a) Remove the terminal insulator from the rectifier end frame.

4. REMOVE GENERATOR BRUSH HOLDER ASSY

REMOVE GENERATOR BRUSH HOLDER ASSY


(a) 100 A: Remove the 2 screws and brush holder.

REMOVE GENERATOR BRUSH HOLDER ASSY


(b) 130 A: Remove the brush holder.

  1.  Remove the plate seal.
  2.  Remove the 2 screws and brush holder.
  3.  Remove the plate seal.

5. REMOVE GENERATOR RECTIFIER END FRAME

REMOVE GENERATOR RECTIFIER END FRAME


(a) Remove the 4 bolts.

REMOVE GENERATOR RECTIFIER END FRAME


(b) Using SST, remove the rectifier end frame.

SST 09950- 40011 (09951- 04020, 09952- 04010, 09953- 04020, 09954- 04010, 09955- 04071, 09957-04010, 09958-04011)

6. REMOVE GENERATOR ROTOR ASSY

REMOVE GENERATOR ROTOR ASSY


(a) Remove the washer and rotor.

7. INSPECT GENERATOR BRUSH HOLDER ASSY

INSPECT GENERATOR BRUSH HOLDER ASSY


(a) 100 A: Using a vernier caliper, measure the exposed brush length.

Standard exposed brush length: 10.5 mm (0.413 in.) Minimum exposed brush length: 4.5 mm (0.177 in.)

If the exposed brush length is less than the minimum, replace the brush holder assy.

INSPECT GENERATOR BRUSH HOLDER ASSY


(b) 130 A: Using a vernier caliper, measure the exposed brush length.

Standard exposed brush length: 10.5 mm (0.413 in.) Minimum exposed brush length: 4.5 mm (0.177 in.)

If the exposed brush length is less than the minimum, replace the brush holder assy.

8. INSPECT GENERATOR ROTOR ASSY

INSPECT GENERATOR ROTOR ASSY


(a) Check that the bearing is not rough or worn.

100 A: If necessary, replace the rotor assy.

130 A: If necessary, replace the rotor bearing.

 INSPECT GENERATOR ROTOR ASSY


(b) Check if the rotor has open circuit.

  1.  Measure the resistance between the slip ring.

Resistance: 2.3 to 2.7 W at 20 C (68 F)

If the resistance is not as specified, replace the generator rotor.

 INSPECT GENERATOR ROTOR ASSY


(c) Check the rotor for ground.

  1.  Measure the resistance between the slip ring and rotor core.

Standard: 1 MW or higher

If the resistance is not as specified, replace the rotor assy.

(d) Check that the slip rings are not rough or scored.

If rough or scored, replace the rotor assy.

 INSPECT GENERATOR ROTOR ASSY


(e) Using vernier calipers, measure the slip ring diameter.

Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum diameter: 14.0 mm (0.551 in.)

If the diameter is less than the minimum, replace the rotor assy.

9. 130 A: REMOVE GENERATOR ROTOR BEARING

REMOVE GENERATOR ROTOR BEARING


(a) Using SST, remove the bearing cover (outside) and bearing.

SST 09820-00021

NOTICE: Be careful not to damage the fan.

(b) Remove the bearing cover (inside).

10. 130 A: INSTALL GENERATOR ROTOR BEARING

INSTALL GENERATOR ROTOR BEARING


(a) Place the generator rotor on the generator pulley.

(b) Install the bearing cover (inside).

(c) Using SST and a press, press in a new bearing.

SST 09820-00031

INSTALL GENERATOR ROTOR BEARING


(d) Using SST, push in the bearing cover (outside).

SST 09285-76010

11. INSPECT GENERATOR DRIVE END FRAME BEARING

INSPECT GENERATOR DRIVE END FRAME BEARING


(a) Check that the bearing is not rough or worn.

If necessary, replace the bearing.

12. REMOVE GENERATOR DRIVE END FRAME BEARING

REMOVE GENERATOR DRIVE END FRAME BEARING


(a) Remove the 4 screws and retainer plate.

REMOVE GENERATOR DRIVE END FRAME BEARING


(b) Using SST and a wooden block, tap out the bearing.

SST 09950- 60010 (09951- 00250), 09950- 70010 (09951-07100)

13. INSTALL GENERATOR DRIVE END FRAME BEARING

INSTALL GENERATOR DRIVE END FRAME BEARING


(a) Using SST and a press, press in a new bearing.

SST 09950- 60010 (09951- 00470), 09950- 70010 (09951-07100)

INSTALL GENERATOR DRIVE END FRAME BEARING


(b) Install the retainer plate with the 4 screws.

Torque: 2.3 NVm (23 kgfVcm, 20 in.Vlbf)

14. INSTALL GENERATOR ROTOR ASSY

 INSTALL GENERATOR ROTOR ASSY


(a) Place the drive end frame on the pulley.

(b) Install the rotor and washer

15. INSTALL GENERATOR RECTIFIER END FRAME

 INSTALL GENERATOR RECTIFIER END FRAME


(a) 100 A: Using deep socket wrench 21 and a press, press in the coil carefully.

(b) 130 A: Using deep socket wrench 20 and a press, press in the coil carefully.

 INSTALL GENERATOR RECTIFIER END FRAME


(c) Tighten the 4 bolts.

Torque: 5.8 NVm (59 kgfVcm, 51 in.Vlbf)

16. INSTALL GENERATOR BRUSH HOLDER ASSY

INSTALL GENERATOR BRUSH HOLDER ASSY


(a) 100 A: Install the brush holder.

  1.  While pushing the 2 brushes to inside the brush holder, insert a pin (f1.0 mm (0.039 in.)) into the brush holder hole.

INSTALL GENERATOR BRUSH HOLDER ASSY


  1. Install the generator brush holder with the 2 screws.

    Torque: 1.8 NVm (18 kgfVcm, 16 in.Vlbf)

  2. Pull out the pin (f1.0 mm (0.039 in.)) from the generator brush holder.

INSTALL GENERATOR BRUSH HOLDER ASSY


(b) 130 A: Install the brush holder.

  1.  Install the plate seal (inside).
  2.  Place the brush holder with the pin facing upward.

    NOTICE: Be careful of the generator brush holder installing direction.

  3.  Tighten the 2 screws.

    Torque: 1.8 NVm (18 kgfVcm, 16 in.Vlbf)

  4.  Align the pins of the brush holder with the holes of the plate seal (outside), and install the plate seal (outside).

17. INSTALL TERMINAL INSULATOR

 INSTALL TERMINAL INSULATOR


(a) Install the terminal insulator.

NOTICE: pay attention to the mounting direction of the terminal insulator.

18. INSTALL GENERATOR REAR END COVER

INSTALL GENERATOR REAR END COVER


(a) Install the rear end cover with the 3 nuts.

Torque: 4.6 NVm (47 kgfVcm, 41 in.Vlbf)

19. INSTALL GENERATOR PULLEY

INSTALL GENERATOR PULLEY


SST 09820-63010 (09820-06010, 09820-06020)

HINT:

INSTALL GENERATOR PULLEY


(a) Install the pulley to the rotor shaft by tightening the generator pulley nut by hand.

(b) Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise with the specified torque.

Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)

NOTICE: Check that SST is secured to the rotor shaft.

INSTALL GENERATOR PULLEY


(c) Mount SST (2) in a vise.

(d) Insert SST (1-A) and (B) into SST (2), and attach the generator pulley nut to SST (2).

INSTALL GENERATOR PULLEY


(e) Tighten the pulley nut by turning SST (1-A) in the direction shown in the illustration.

Torque: 111 NVm (1,125 kgfVcm, 81 ftVlbf) (f) Remove the generator from SST (2).

INSTALL GENERATOR PULLEY


(g) Turn SST (1-B), and remove SST (1-A), (B).

(h) Turn the pulley, and check that the pulley moves smoothly.

Replacement
1. REMOVE GENERATOR ASSY (a) Remove the wire harness clamp. (b) Disconnect the generator connector. (c) Open the terminal cap, remove the nut and disconnect the generator wire. (d) Loosen ...

Front suspension
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