Section 175 (Charging): Generator: Reassembly

WARNING: This page is about a different car, the 2002 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.

Install rotor to drive end frame.
1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
  
  Fig 1: Installing Rotor To Drive End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install coil assembly.
1. Place the generator washer on the rotor.
  
  Fig 2: Placing Generator Washer On Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 29 mm socket wrench and press, slowly press in the coil assembly.
  
  Fig 3: Pressing In Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the coil assembly with the 4 bolts.
  Torque : 5.8 N.m (59 kgf.cm, 51 in.lbf)
  
  Fig 4: Locating Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install pulley.
1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
2. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
  SST 09820-63011
  
  Torque : 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 5: Tightening Pulley Nut By Hand
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
  
  Fig 6: Mounting SST in Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  Torque : 110.5 N.m (1,125 kgf.cm, 81 ft.lbf)
7. Remove the generator from SST (C).
  
  Fig 7: Turning SST In Proper Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn SST (B), and remove SST (A and B).
  
  Fig 8: Removing SST A & B
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install brush holder.
1. Place the front seal plate to the coil assembly.
  
  Fig 9: Placing Front Seal Plate To Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the brush holder on the coil assembly.
  NOTE: Be careful of the holder installation direction.
3. Install the 2 screws.
  Torque : 1.8 N.m (18 kgf.cm, 16 in.lbf)
4. Place the real seal plate on the brush holder.
  
  Fig 10: Placing Brush Holder To Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install rear end cover.
1. Install the terminal insulator.
2. Install the end cover with the 3 nuts.
  Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)
  
  Fig 11: Identifying Rear End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check that rotor rotates smoothly.