Charging System (Service Information): Removal & Installation Lexus RX III

REMOVAL

1. PRECAUTION (w/ Air Suspension) NOTE: Be sure to read Precaution thoroughly before servicing. Refer to «PRECAUTION»(ref-400808-S39927796452011051800000) .
2. PRECAUTION (w/ Navigation System for HDD) NOTE: After the engine switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal. Refer to «PRECAUTION»(ref-400817-S06395767762011051800000) .
3. REMOVE FRONT BUMPER ASSEMBLY HINT: Refer to «REMOVAL»(ref-400813-S35322236252011051800000) .
4. REMOVE RADIATOR ASSEMBLY WITH FAN SHROUD AND FAN MOTOR HINT: Refer to «REMOVAL»(ref-400800-S34662827102011051800000) .
5. REMOVE V-RIBBED BELT HINT: Refer to «REMOVAL»(ref-400790-S08717028402011051800000) .
6. REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 34»(ref-400790-S42173954232011051800000)
7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system. Refer to «PRECAUTION»(ref-400811-S15765720172011051800000) . NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-400649-S34584305262011051800000) .
8. REMOVE GENERATOR ASSEMBLY Turn back the terminal cap. Remove the nut and disconnect the wire harness from terminal B. Disconnect the generator connector from the generator assembly. Disconnect the connector from the compressor and magnetic clutch. Disconnect the wire harness clamps. Remove the bolt and nut from the cylinder block. Disconnect the wire harness clamp and remove the generator bracket. Remove the 2 bolts. Remove the bolt and the wire harness clamp stay.

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1. REMOVE GENERATOR REAR END COVER Remove the 3 nuts and generator rear end cover.
2. REMOVE GENERATOR TERMINAL INSULATOR Remove the terminal insulator from the generator coil.
3. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY Remove the 2 screws and brush holder from the generator coil.
4. REMOVE GENERATOR COIL ASSEMBLY Remove the 4 bolts. Using SST, remove the generator coil assembly. TEXT IN ILLUSTRATION *1 Turn *2 Hold SST: 09950-40011 09951-04020 09952-04010 09953-04020 09954-04010 09955-04071 09957-04010 09958-04011
5. REMOVE GENERATOR CLUTCH PULLEY Using a screwdriver, remove the generator pulley cap. Mount the generator drive end frame in a vise tightly. Confirm SST (A) and (B) shown in the illustration. TEXT IN ILLUSTRATION *1 SST (A) *2 SST (B) SST: 09820-63021 Place the rotor shaft end into SST (A). TEXT IN ILLUSTRATION *1 Rotor Shaft *2 SST (A) Fit SST (B) to the clutch pulley. TEXT IN ILLUSTRATION *1 Clutch Pulley *2 SST (B) *3 SST (A) Loosen the pulley by turning SST (B) in the direction shown in the illustration. NOTE: Check that the drive end frame is secured in the vise tightly. Hold SST (A) tightly during the operation. TEXT IN ILLUSTRATION *1 SST (B) *2 SST (A) Remove the generator assembly from SST. Remove the clutch pulley from the rotor shaft.
6. REMOVE GENERATOR ROTOR ASSEMBLY Remove the generator washer. Remove the generator rotor assembly.

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1. INSPECT GENERATOR CLUTCH PULLEY Hold the center of the pulley, and confirm that the outer ring turns counterclockwise and does not turn clockwise. TEXT IN ILLUSTRATION *1 Free *2 Lock If the result is not as specified, replace the clutch pulley.
2. INSPECT GENERATOR DRIVE END FRAME BEARING Check that the bearing is not rough or worn. OK The bearing rotates smoothly. If the bearing does not rotate smoothly, replace the bearing.
3. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY Using a vernier caliper, measure the length of the exposed brushes. TEXT IN ILLUSTRATION *1 Length Standard exposed length 9.5 to 11.5 mm (0.375 to 0.452 in.) Minimum exposed length 4.5 mm (0.178 in.) If the exposed length is less than the minimum, replace the brush holder assembly.
4. INSPECT GENERATOR ROTOR ASSEMBLY Check that the generator rotor bearing is not rough or worn. If necessary, replace the generator rotor assembly. Check the generator rotor for an open circuit. TEXT IN ILLUSTRATION *1 Slip Ring *2 Ohmmeter Using an ohmmeter, measure the resistance between the slip rings. Standard Resistance Condition Specified Condition Approx. 20°C (68°F) 1.5 to 1.9 ohms If the result is not as specified, replace the generator rotor assembly. Check the rotor for a short to ground. TEXT IN ILLUSTRATION *1 Slip Ring *2 Rotor *3 Ohmmeter Using an ohmmeter, measure the resistance between the slip ring and rotor. Standard Resistance Tester Connection Specified Condition Slip ring - Rotor 1 Mohms or higher If the result is not as specified, replace the generator rotor assembly. Using a vernier caliper, measure the slip ring diameter. TEXT IN ILLUSTRATION *1 Diameter Standard diameter 14.2 to 14.4 mm (0.560 to 0.566 in.) Minimum diameter 14.0 mm (0.552 in.) If the diameter is less than the minimum, replace the generator rotor assembly.

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1. REPLACE GENERATOR DRIVE END FRAME BEARING Remove the 4 screws and retainer plate from the drive end frame. Using SST and a hammer, tap out the drive end frame bearing from the drive end frame. SST: 09950-60010 09951-00250 SST: 09950-70010 09951-07100 Using SST and a press, press in a new generator drive end frame bearing. SST: 09950-60010 09951-00470 SST: 09950-70010 09951-07100 Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate. TEXT IN ILLUSTRATION *1 Tab *2 Cutout Install the 4 screws. Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)

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1. INSTALL GENERATOR ROTOR ASSEMBLY Place the drive end frame on the clutch pulley. Install the generator rotor assembly to the drive end frame. Place a new generator washer on the generator rotor.
2. INSTALL GENERATOR CLUTCH PULLEY Temporarily install the clutch pulley onto the rotor shaft. Mount the generator drive end frame in a vise tightly. Confirm SST (A) and (B) shown in the illustration. TEXT IN ILLUSTRATION *1 SST (A) *2 SST (B) SST: 09820-63021 Place the rotor shaft end into SST (A). TEXT IN ILLUSTRATION *1 Rotor Shaft *2 SST (A) Fit SST (B) to the clutch pulley. TEXT IN ILLUSTRATION *1 Clutch Pulley *2 SST (B) *3 SST (A) Tighten the pulley by turning SST (B) in the direction shown in the illustration. TEXT IN ILLUSTRATION *1 SST (B) *2 SST (A) *3 Fulcrum Length: 318 mm without SST Torque: 111 N*m (1132 kgf*cm, 82 ft.*lbf) with SST Torque: 89 N*m (908 kgf*cm, 66 ft.*lbf) NOTE: Use a torque wrench with a fulcrum length of 318 mm (1.043 ft.). 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. Remove the generator assembly from SST. Check that the clutch pulley rotates smoothly. Install a new generator pulley cap to the clutch pulley.
3. INSTALL GENERATOR COIL ASSEMBLY Using a deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly. TEXT IN ILLUSTRATION *1 Deep Socket Wrench (21 mm) Install the 4 bolts. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.039 in.) pin into the brush holder hole. TEXT IN ILLUSTRATION *1 Pin Install the brush holder assembly to the generator coil with the 2 screws. TEXT IN ILLUSTRATION *1 Pin Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) Pull out the pin from the generator brush holder.
5. INSTALL GENERATOR TERMINAL INSULATOR Install the terminal insulator to the generator coil. NOTE: Pay attention to the installation direction of the terminal insulator.
6. INSTALL GENERATOR REAR END COVER Install the generator rear end cover to the generator coil with the 3 nuts. Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)

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1. INSTALL GENERATOR ASSEMBLY Install the wire harness clamp stay with the bolt. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) Connect the wire harness clamp. Install the generator assembly to the cylinder block with the generator bracket, bolt and nut. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Install the 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Connect the generator connector to the generator assembly. Install the generator wire with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) Install the terminal cap. Connect the wire harness clamps. Connect the magnetic clutch connector to the compressor and magnetic clutch.
2. INSTALL V-RIBBED BELT HINT: Refer to «INSTALLATION»(ref-400790-S28085469722011051800000) .
3. INSTALL RADIATOR ASSEMBLY WITH FAN SHROUD AND FAN MOTOR HINT: Refer to «INSTALLATION»(ref-400800-S15792145172011051800000) .
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-400649-S12881576452011051800000) .
5. INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 113»(ref-400790-S30060480932011051800000)
6. INSTALL FRONT BUMPER ASSEMBLY HINT: Refer to «INSTALLATION»(ref-400813-S23024648612011051800000) .

INSTALLATION

1. INSTALL GENERATOR ASSEMBLY Install the wire harness clamp stay with the bolt. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) Connect the wire harness clamp. Install the generator assembly to the cylinder block with the generator bracket, bolt and nut. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Install the 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Connect the generator connector to the generator assembly. Install the generator wire with the nut. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) Install the terminal cap. Connect the wire harness clamps. Connect the magnetic clutch connector to the compressor and magnetic clutch.
2. INSTALL V-RIBBED BELT HINT: Refer to «INSTALLATION»(ref-400790-S02781114482011051800000) .
3. INSTALL RADIATOR ASSEMBLY WITH FAN SHROUD AND FAN MOTOR HINT: Refer to «INSTALLATION»(ref-400800-S30883477082011051800000) .
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-400649-S34584305262011051800000) .
5. INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 113»(ref-400790-S01050581782011051800000)
6. INSTALL FRONT BUMPER ASSEMBLY HINT: Refer to «INSTALLATION»(ref-400813-S23024648612011051800000) .