LEXUS ES300 2005 Repair Manual

A86392
Generator Pulley
Drive End Frame Assy
GeneratorGenerator Rotor AssyGenerator Washer
Generator Coil AssyTerminal Insulator
Generator
Brush Holder Assy
Generator
Rear End Cover
x4

Non-reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
5.8 (59, 51 in.Vlbf)
1.8 (18, 16 in.Vlbf)
4.6 (47, 41 in.Vlbf)
111 (1,125, 81)
x2x3 19-20
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
2352 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)

190SL-01
A86379
(a)
(b)
(c)
(a)
Terminal Cap
A87594
B
AC
A87593
B
A
A87595
(h)
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
19-21
2353 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE GENERATOR ASSY
(a) Remove the 2 wire harness clamps.
(b) Disconnect the generator connector.
(c) Open the terminal cap.
(d) Remove the nut, then disconnect the generator wire.
(e) Loosen bolts A and B.
(f) Loosen bolt C to lessen the tension of the V-ribbed belt
No.1.
(g) Remove bolts A and B, then remove the generator.
(h) Remove the bolt, then remove the wiring harness clamp
bracket.

A87593
B
A
A87594
B
AC 19-22
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
2354 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
3. INSTALL GENERATOR ASSY
(a) Install the wiring harness clamp bracket with the bolt.
Torque: 8.4 NVm (86 kgfVcm, 74 in.Vlbf)
(b) Temporarily install the generator with bolts A and B.
(c) Adjust the V-ribbed belt No. 1 tension by tightening bolt
C (see page 14-1).
(d) Tighten bolts A and B.
Torque:
18 NVm (180 kgfVcm, 13 ftVlbf) for bolt A
58 NVm (591 kgfVcm, 43 ftVlbf) for bolt B
(e) Install the generator wire with the nut.
Torque: 9.8 NVm (100 kgfVcm, 7 ftVlbf)
(f) Connect the generator connector.
(g) Install the wire harness clamp.
4. INSPECT DRIVE BELT (See page 14-1)
5. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
6. SYSTEM INITIALIZATION (See page 19-15)

190SM-01
A81658
SST 1-A
SST 1-B
Turn
Hold
A81659
SST 2
Insert
SST 1
A81660
TurnSST1-A
A81661
SST 1-A
SST 1-B
Turn
Hold
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
19-23
2355 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
1. REMOVE GENERATOR PULLEY
SST 09820-6301 1 (09820-06010, 09820-06020)
HINT:
SST 1-A and B09820 - 06010
SST 209820 - 06020
(a) Hold SST 1-A with a torque wrench, then 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.
(b) Clamp SST 2 in a vise.
(c) Insert SST 1-A and B into SST 2, then 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 a half turn.
(e) Remove the generator from SST 2.
(f) Turn SST 1-B, then remove SST 1-A and B.
(g) Remove the pulley nut, then remove the generator pulley.

A81662
Pulley
A81146
A81147
A81148
A81663
SST
HoldTurn
19-24
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
2356 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
2. REMOVE GENERATOR BRUSH HOLDER ASSY
(a) Place the generator on the generator pulley.
(b) Remove the 3 nuts, then remove the generator rear end
cover.
(c) Remove the terminal insulator from the generator coil.
(d) Remove the 2 screws, then remove the generator brush
holder.
3. REMOVE GENERATOR COIL ASSY
(a) Remove the 4 bolts.
(b) Using SST, remove the generator coil.
SST 09950- 40011 (09951- 04020, 09952- 04010,
09953- 04020, 09954- 04010, 09955- 04071,
09957-04010, 09958-04011)

A81664
Generator Washer
A79305
Length
A79306
A88420
Ohmmeter Slip Ring
A88421
Ohmmeter Slip RingRotor Core
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
19-25
2357 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
4. REMOVE GENERATOR ROTOR ASSY
(a) Remove the generator washer and generator rotor.
5. INSPECT GENERATOR BRUSH HOLDER ASSY
(a) Inspect the length.
(1) Using vernier calipers, 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 minimum, replace the
generator brush holder.
6. INSPECT GENERATOR ROTOR ASSY
(a) Check that the bearing is not rough or worn.
If necessary, replace the generator rotor.
(b) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the slip rings.
Resistance: 2.3 to 2.7W at 20
C (68
F)
If the resistance is not as specified, replace the generator rotor.
(c) Check the continuity.
(1) Using an ohmmeter, check that there is no continu-
ity between the slip ring and rotor core.
If there is continuity, replace the generator rotor.
(d) Check the appearance.
(1) Check that the slip rings are not rough or scored.
If rough or scored, replace the generator rotor.

A75676
Diameter
A81670
Generator
PulleyGenerator Washer
A81671
Deep Socket
Wrench 21
A81148
A79315
Pin (f1.0 mm (0.039 in.))
19-26
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
2358 Author
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:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(e) Inspect the diameter.
(1) Using vernier calipers, measure the slip ring diame-
ter.
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 minimum, replace the generator ro-
tor.
7. INSTALL GENERATOR ROTOR ASSY
(a) Place the generator drive end frame on the generator
pulley.
(b) Install the generator rotor and generator washer.
8. INSTALL GENERATOR COIL ASSY
(a) Using a deep socket wrench 21 and press, press in the
generator coil carefully.
(b) Tighten the 4 bolts.
Torque: 5.8 NVm (59 kgfVcm, 51 in.Vlbf)
9. INSTALL GENERATOR BRUSH HOLDER ASSY
(a) While pushing the 2 brushes to inside the brush holder,
insert a pin (f1.0 mm (0.039 in.)) into the brush holder
hole.

A81672
Pin (f1.0 mm (0.039 in.)
A81146
A81164
A81658
SST 1-A
SST 1-B
Turn
Hold
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
19-27
2359 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Install the generator brush holder with the 2 screws.
Torque: 1.8 NVm (18 kgfVcm, 16 in.Vlbf)
(c) Pull out the pin (f1.0 mm (0.039 in.)) from the generator
brush holder.
(d) Install the terminal insulator.
NOTICE:
Pay attention to the mounting orientation of the terminal in-
sulator.
(e) Install the generator rear end cover with the 3 nuts.
Torque: 4.6 NVm (47 kgfVcm, 41 in.Vlbf)
10. INSTALL GENERATOR PULLEY
SST 09820-6301 1 (09820-06010, 09820-06020)
HINT:
SST 1-A and B09820 - 06010
SST 209820 - 06020
(a) Install the generator pulley to the rotor shaft by tightening
the generator pulley nut by hand.
(b) Hold SST 1-A with a torque wrench, then 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.

A81659
SST 2
Insert
SST 1
A81673
TurnSST1-A
A81661
SST 1-A
SST 1-B
Turn
Hold 19-28
- STARTING & CHARGINGGENERATOR ASSY (3MZ-FE)
2360 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Clamp SST 2 in a vise.
(d) Insert SST 1-A and B into SST 2, then attach the genera-
tor pulley nut to SST 2.
(e) Tighten the generator 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, then remove SST 1-A and B.
(h) Turn the generator pulley, then check that the generator
pulley moves smoothly.

5002J-08
- STEERING COLUMNSTEERING
50-1
2562 Author
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STEERING
PRECAUTION
1. HANDLING PRECAUTIONS ON STEERING SYSTEM
(a) Care must be taken when replacing parts. Incorrect replacement they could affect the performance
of the steering system and result in a driving hazard.
2. HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM
(a) The LEXUS ES330
is equipped with SRS (Supplemental Restraint System) such as the driver airbag
and front passenger airbag. Failure to carry out service operation in correct sequence could cause the
SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing
(including removal or installation of parts, inspection or replacement), be sure to read the precaution-
ary notice for the supplemental restraint system (See page 60-1).