Charging Systems: Charging: Generator: Reassembly

INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
Fig 1: Identifying Pulley
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INSTALL GENERATOR COIL ASSEMBLY
1. Place the generator washer on the rotor.
  
  Fig 2: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, slowly press in the coil assembly.
  SST 09285-76010
  
  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 GENERATOR 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 SST (B) Clockwise To Specified Torque
  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: Inserting SST (B) Into SST (C)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  Torque: 111 N*m (1,125 kgf*cm, 81 ft.*lbf)
7. Remove the generator from SST (C).
  
  Fig 7: Tightening Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn SST (B), and remove SST (A and B).
Fig 8: Removing SST (A And B)
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INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. Place the front seal plate on the coil assembly.
  
  Fig 9: Identifying Front Seal Plate On Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the brush holder on the coil assembly with the pin facing upward.
  NOTE: Be careful of the holder installation direction.
3. Install the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
  
  Fig 10: Identifying Brush Holder On Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the pins of the brush holder with the holes of the rear seal plate, and install the rear seal plate.
Fig 11: Aligning Pins Of Brush Holder With Holes Of Rear Seal Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the terminal insulator.
  NOTE: Be careful of the terminal insulator installation direction.
  
  Fig 12: Identifying Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the end cover with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*ibf)