Toyota Highlander Service Manual: Overhaul
1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
HINT:
(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.
(b) Mount SST (2) in a vise.
(c) Insert SST (1-A, B) into SST (2), and attach the pulley nut to SST (2).
(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).
(f) Turn SST (1-B) and remove SST (1-A, B).
(g) Remove the pulley nut and pulley.
2. 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
(a) Remove the terminal insulator from the rectifier end frame.
4. REMOVE GENERATOR BRUSH HOLDER ASSY
(a) 100 A: Remove the 2 screws and brush holder.
(b) 130 A: Remove the brush holder.
- Remove the plate seal.
- Remove the 2 screws and brush holder.
- Remove the plate seal.
5. REMOVE GENERATOR RECTIFIER END FRAME
(a) Remove the 4 bolts.
(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
(a) Remove the washer and rotor.
7. 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.
(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
(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.
(b) Check if the rotor has open circuit.
- 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.
(c) Check the rotor for ground.
- 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.
(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
(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
(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
(d) Using SST, push in the bearing cover (outside).
SST 09285-76010
11. 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
(a) Remove the 4 screws and retainer plate.
(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
(a) Using SST and a press, press in a new bearing.
SST 09950- 60010 (09951- 00470), 09950- 70010 (09951-07100)
(b) Install the retainer plate with the 4 screws.
Torque: 2.3 NVm (23 kgfVcm, 20 in.Vlbf)
14. 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
(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.
(c) Tighten the 4 bolts.
Torque: 5.8 NVm (59 kgfVcm, 51 in.Vlbf)
16. INSTALL GENERATOR BRUSH HOLDER ASSY
(a) 100 A: Install the brush holder.
- 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 the generator brush holder with the 2 screws.
Torque: 1.8 NVm (18 kgfVcm, 16 in.Vlbf)
- Pull out the pin (f1.0 mm (0.039 in.)) from the generator brush holder.
(b) 130 A: Install the brush holder.
- Install the plate seal (inside).
- Place the brush holder with the pin facing upward.
NOTICE: Be careful of the generator brush holder installing direction.
- Tighten the 2 screws.
Torque: 1.8 NVm (18 kgfVcm, 16 in.Vlbf)
- 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
(a) Install the terminal insulator.
NOTICE: pay attention to the mounting direction of the terminal insulator.
18. 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
SST 09820-63010 (09820-06010, 09820-06020)
HINT:
(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.
(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).
(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).
(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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More about Toyota Highlander:
Glass hatch
Opening the glass hatch
The glass hatch can be opened using the glass hatch opener.
vehicles without a smart key system
press the button to pop up the
glass hatch.
Raise the glass hatch using the
knob
The glass hatch cannot be open
when the back door is locked.
Unlock t ...
