Charging Systems: Generator: Reassembly

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.