Section 15 (Charging System): Generator: Reassembly

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL GENERATOR ROTOR BEARING
1. Using SST and a press, press a new generator rotor bearing into the drive end frame.
  SST 09950-60010 (09951-00500), 09950-70010 (09951-07100)
  
  Fig 1: Installing Generator Rotor Bearing Into Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the protrusions of the retainer with the drive end frame cutouts, and then install the retainer with the 4 screws
  Torque: 3.0 N*m (30 kgf*cm, 27 in.*lbf)
  
  Fig 2: Identifying Retainer Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR ROTOR ASSEMBLY
1. Install the generator rotor assembly.
  
  Fig 3: Locating Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator washer.
  
  Fig 4: Locating Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Using SST and a press, press the generator coil assembly into the drive end frame
  SST 09612-70100
  
  Fig 5: Installing Generator Coil Assembly Into Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the 4 through bolts
  Torque: 7.5 N*m (76 kgf*cm, 68 in.*lbf)
  
  Fig 6: Locating Generator Coil Assembly Through Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. Insert a pin (diameter 1 0 mm (0 039 in.)) into the generator brush holder assembly to secure the 2 brushes in place
  
  Fig 7: Identifying Pin Into Generator Brush Holder Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator brush holder to the generator coil assembly with the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Remove the pin (diameter 1 0 mm(0.039 in)).
  
  Fig 8: Locating Generator Brush Holder Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR TERMINAL INSULATOR
1. Install the generator terminal insulator to the generator coil assembly
  
  Fig 9: Identifying Generator Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the generator rear end cover to the generator coil assembly with the 3 nuts
  Torque: 4.6 N*m (47 kgf*cm, 42 in.*lbf)
  
  Fig 10: Locating Generator Rear End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR PULLEY
1. Install the generator pulley, and temporarily install the pulley lock nut
2. Install SST1-A to the pulley shaft
  SST 09820-63011 (09820-06010, 09820-06021)
  
  Fig 11: Tightening Pulley Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install SST1-B to SST1-A
4. While holding SST1-A on the pulley shaft area, tighten SST1-B to the specified torque
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  NOTE: Securely attach SST1-A to the pulley shaft.
  
  HINT.
  
  Read SST1-B tightening torque by using the reactive torque of SST1-A
5. Mount 2 faces of SST2 in a vise.
6. With SST1 -A and B attached to the generator, insert the pulley lock nut into the hexagon portion of SST2.
  
  Fig 12: Mounting Faces Of SST2 In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. To tighten the generator pulley nut, rotate SST1-A in the direction shown in the illustration.
  Torque: 133 N*m (1351 kgf*cm, 98 ft.*lbf)
  
  Fig 13: Tightening Generator Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the generator from SST2.
9. While holding SST1-B in place, rotate SST1 -A to the right to loosen it Then remove SST1-A and B from the generator.
10. Check that the generator pulley rotates smoothly