Charging Systems: Charging: Generator: Reassembly

PLACE DRIVE END FRAME ON PULLEY

Fig 1: Placing Drive End Frame On Pulley

INSTALL ROTOR TO DRIVE END FRAME
INSTALL RECTIFIER END FRAME
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 rectifier end frame.
  
  Fig 3: Pressing In Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 3 nuts.
  1. Torque: 4.5 N.m (46 kgf.cm, 48 in.lbf)
4. Install the wire clip with the nut.
  1. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  Fig 4: Installing Wire Clip With Nut
  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.
  1. SST 09820-6301 1
  2. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
  Fig 5: Tightening SST Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check that SST (A) is secured to the pulley shaft.
4. Mount SST (C) in a vise.
  
  Fig 6: Mounting SST In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
6. To torque the pulley nut, turn SST (A) in the direction shown in Fig 7 .
  1. Torque: 110.5 N.m (1,125 kgf.cm, 81 ft.lbf)
  Fig 7: Turning SST To Tighten Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the generator from SST (C).
8. Turn SST (B), and remove SST (A and B).
INSTALL RECTIFIER HOLDER
1. Install the 4 rubber insulators on the lead wires.
  
  Fig 8: Installing Rubber Insulators On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier holder while pushing it with the 4 screws.
  1. Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
  Fig 9: Installing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
1. Place the seal plate on the rectifier end frame.
  
  Fig 10: Placing Seal Plate On Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the voltage regulator and brush holder on the rectifier end frame.
  NOTE: Be careful of the holder installation direction.
  
  Fig 11: Placing Voltage Regulator & Brush Holder On Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 5 screws.
  1. Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
INSTALL REAR END COVER
1. Place the brush holder cover on the brush holder.
  
  Fig 12: Placing Brush Holder Cover On Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the end cover and plate terminal with the bolt and 3 nuts.
  1. Torque:
  2. 4.4 N.m (45 kgf.cm, 39 in.lbf) for nut
  3. 3.9 N.m (39 kgf.cm, 35 in.lbf) for bolt
  Fig 13: Installing End Cover & Plate Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the terminal insulator with the nut.
  1. Torque: 6.5 N.m (67 kgf.cm, 58 in.lbf)
CHECK THAT ROTOR ROTATES SMOOTHLY