Toyota Avalon (XX50): Generator

*1

GENERATOR ASSEMBLY

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WIRE HARNESS CLAMP BRACKET

*3

GENERATOR ASSEMBLY BRACKET

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V-BANK COVER SUB-ASSEMBLY

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

*1

GENERATOR BRUSH HOLDER ASSEMBLY

*2

GENERATOR COIL ASSEMBLY

*3

GENERATOR DRIVE END FRAME BEARING

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GENERATOR PULLEY WITH CLUTCH

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GENERATOR REAR END COVER

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GENERATOR ROTOR ASSEMBLY

*7

GENERATOR TERMINAL INSULATOR

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GENERATOR DRIVE END FRAME

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RETAINER PLATE

*10

BEARING COVER PACKING

*11

GENERATOR PULLEY CAP

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N*m (kgf*cm, ft.*lbf) : Specified torque

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For use with SST

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Non-reusable part

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(a) Using a screwdriver, remove the generator pulley cap from the generator pulley with clutch.

NOTICE:

Do not reuse the generator pulley cap.

(a) Remove the 3 bolts and generator rear end cover from the generator coil assembly.

(a) Remove the generator terminal insulator from the generator coil assembly.

(a) Remove the 2 screws and generator brush holder assembly from the generator coil assembly.

(a) Remove the 4 bolts.

(b) Using SST, remove the generator coil assembly from the generator rotor assembly.

SST: 09950-40011

09951-04020

09952-04010

09953-04020

09954-04010

09955-04071

09957-04010

09958-04011

(c) Remove the bearing cover packing.

NOTICE:

If the bearing cover packing breaks, remove the broken pieces completely.

HINT:

The bearing cover packing may be installed on the generator rotor assembly.

(b) Install SST (A) and (B) to the generator pulley with clutch as shown in the illustration.

SST: 09820-63021

NOTICE:

Securely attach SST to the generator pulley with clutch and rotor shaft.

(c) Loosen the generator pulley with clutch by turning SST (B) as shown in the illustration.

NOTICE:

• Check that the generator drive end frame is secured in the vise tightly.

• Hold SST (A) tightly during the operation.

(a) Remove the generator rotor assembly from the generator drive end frame.

(a) Remove the 4 screws and retainer plate from the generator drive end frame.

(b) Using SST and a hammer, tap out the generator drive end frame bearing from the generator drive end frame.

SST: 09950-60010

09951-00250

SST: 09950-70010

09951-07100

Free

Lock

(a) Using a vernier caliper, measure the length of the exposed brushes.

Standard Exposed Brush Length:

9.5 to 11.5 mm (0.374 to 0.453 in.)

Minimum Exposed Brush Length:

4.5 mm (0.177 in.)

If the brush length is less than the minimum, replace the generator brush holder assembly.

(a) Check the generator rotor assembly for an open circuit.

(1) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

If the result is not as specified, replace the generator rotor assembly.

(b) Check the generator rotor assembly for a short to ground.

(1) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

If the result is not as specified, replace the generator rotor assembly.

(c) Check that the generator rotor bearing is not rough or worn and that it rotates smoothly.

If the generator rotor bearing is rough or worn, or does not rotate smoothly, replace the generator rotor assembly.

(d) Check the slip ring.

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

If the slip rings are rough or scored, replace the generator rotor assembly.

(2) Using a vernier caliper, measure the slip ring diameter.

Standard Diameter:

14.2 to 14.8 mm (0.559 to 0.583 in.)

Minimum Diameter:

14.0 mm (0.551 in.)

If the diameter is less than the minimum, replace the generator rotor assembly.

(a) Check that the generator drive end frame bearing is not rough or worn and that it rotates smoothly.

If the generator drive end frame bearing is rough or worn, or does not rotate smoothly, replace the generator drive end frame bearing.

(b) Install the generator assembly bracket with the 2 bolts in the order shown in the illustration.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(a) Using SST and a press, install a new generator drive end frame bearing to the generator drive end frame.

SST: 09950-60010

09951-00470

SST: 09950-70010

09951-07100

(b) Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.

(b) Install the generator rotor assembly to the generator drive end frame.

(c) Place the rotor shaft end into SST (A).

SST: 09820-63021

(e) Tighten the generator pulley with clutch by turning SST (B) as shown in the illustration.

Torque:

Specified tightening torque :

80 N·m {816 kgf·cm, 59 ft·lbf}

HINT:

• Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

  Click here

• When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (1.312 ft.)): 64 N*m (653 kgf*cm, 47 ft.*lbf)

(a) Install a new bearing cover packing.

NOTICE:

Align the protrusions of the bearing cover packing with the grooves of the generator coil assembly when installing.

(b) Using a 21 mm socket wrench and press, slowly press the generator coil assembly to install it.

(c) Install the 4 bolts.

Torque:

5.6 N·m {57 kgf·cm, 50 in·lbf}

(a) While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder assembly hole.

*a

Pin (1.0 mm)

Pull out

(a) Install the generator terminal insulator to the generator coil assembly.

NOTICE:

Be sure to install the generator terminal insulator in the correct direction.

(a) Install the generator rear end cover to the generator coil assembly with the 3 bolts.

Torque:

4.6 N·m {47 kgf·cm, 41 in·lbf}

Click here

Battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane departure alert system (w/ Steering Control)

Pre-collision system

Intelligent clearance sonar system*

Lighting System (for Gasoline Model with Cornering Light)

Memorize steering angle neutral point

Parking assist monitor system

Panoramic view monitor system

Front bumper assembly (w/ Panoramic view monitor system)

Front television camera view adjustment

Panoramic view monitor system

for Initialization

for Calibration

Front bumper assembly (w/ Intuitive Parking Assist System)

• Measure ultrasonic sensor detection angle
• Ultrasonic sensor detection angle registration

• Intelligent clearance sonar system
• Intuitive parking assist system

(a) Open the terminal cap.

(d) Disconnect the generator assembly connector.

(h) Remove the 2 bolts and generator assembly bracket.

(i) Remove the 2 bolts and generator assembly.