Toyota RAV4 manuals

Toyota Sienna Service Manual: Reassembly

1. INSTALL GENERATOR ROTOR ASSEMBLY

INSTALL GENERATOR ROTOR ASSEMBLY

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

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

INSTALL GENERATOR ROTOR ASSEMBLY

(c) Place a new generator washer on the generator rotor.

2. INSTALL GENERATOR COIL ASSEMBLY

INSTALL GENERATOR COIL ASSEMBLY

(a) Using a deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly.

INSTALL GENERATOR COIL ASSEMBLY

(b) Install the 4 bolts.

Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)

3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

(a) While pushing the 2 brushes into the generator brush holder assembly, insert a φ1.0 mm (0.039 in.) pin into the brush holder hole.

INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

(b) Install the brush holder assembly to the generator coil with the 2 screws.

Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) (c) Pull out the pin from the generator brush holder.

4. INSTALL GENERATOR TERMINAL INSULATOR

INSTALL GENERATOR TERMINAL INSULATOR

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

NOTICE: Pay attention to installation direction of the terminal insulator.

5. INSTALL GENERATOR REAR END COVER

 INSTALL GENERATOR REAR END COVER

(a) 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)

6. INSTALL GENERATOR CLUTCH PULLEY

(a) Temporarily install the clutch pulley onto the rotor shaft.

INSTALL GENERATOR CLUTCH PULLEY

(b) Set SST (A) and (B).

SST 09820-63020

INSTALL GENERATOR CLUTCH PULLEY

(c) Clamp SST (A) in a vise.

NOTICE: Be sure to fix the flat surface of SST (A) in a vise.

INSTALL GENERATOR CLUTCH PULLEY

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

INSTALL GENERATOR CLUTCH PULLEY

(e) Fit SST (B) to the clutch pulley.

INSTALL GENERATOR CLUTCH PULLEY

(f) Tighten the pulley by turning SST (B) in the direction shown in the illustration.

Torque: without SST 110 N*m (1125 kgf*cm, 81 ft.*lbf)

with SST 84 N*m (857 kgf*cm, 62 ft.*lbf)

NOTICE:
  • Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).
  • This torque value is effective when SST is parallel to a torque wrench.
  • Hold the generator assembly tightly.

(g) Remove the generator assembly from SST.

(h) Check that the clutch pulley rotates smoothly.

(i) Install a new clutch pulley cap to the clutch pulley.

Replacement
1. REPLACE GENERATOR DRIVE END FRAME BEARING (a) Remove the 4 screws and retainer plate from the drive end frame. (b) Using SST and a hammer, tap out the drive end frame bearing from the d ...

Installation
1. Install generator assembly (a) Install the bracket with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (b) Install the wire harness clamp stay. Torque: 8.4 N*m (86 kgf*cm, 74 in. ...

Other materials:

Grocery bag hooks
The hooks are designed to hang things like a grocery bag. Type A (front seatback) (if equipped) Type B (third seatback) Type C (luggage compartment) Type D (luggage compartment) Pull the hook up. WARNING Type C: When not in use, keep the grocery ...

Fail-safe chart
If any of the following DTCs are set, the ECM enters fail-safe mode to allow the vehicle to be driven temporarily. HINT:  *1: The vehicle can be driven slowly when the accelerator pedal is depressed firmly and slowly. If the accelerator pedal is depressed quickly, the vehicle may ...

Installation
1. INSTALL STEERING PAD  Support the steering pad with one hand as shown in the illustration.  Connect the 2 connectors to the steering pad. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.  Connect the horn connector. ...

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