Charging System: 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: Placing Drive End Frame On Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Place the generator washer on the rotor.
  
  Fig 2: Identifying Generator Washer On Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 21 mm socket wrench and a press, slowly press in the coil assembly.
  
  Fig 3: Pressing Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 4 bolts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 4: Locating Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. While pushing the 2 brushes toward the inside of the brush holder, insert a pin (diameter: 1.0 mm (0.0394 in.)) into the brush holder hole.
  
  Fig 5: Inserting Pin Into Brush Holder Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator brush holder with the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Pull out the pin from the generator brush holder.
Fig 6: Locating Generator Brush Holder With Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the terminal insulator to the generator rectifier end frame.
  NOTE: Pay attention to the mounting orientation of the terminal insulator.
  
  Fig 7: Identifying Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the end cover with the 3 nuts.
  Torque: 4.6 N*m (46 kgf*cm, 40 in.*lbf)
  
  Fig 8: Locating End Cover With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL GENERATOR PULLEY

SST 09820-63011 (09820-06010, 09820-06021)

HINT:

TOOL REFERENCE CHART

SST 1-A and B	09820-06010
SST 2	09820-06021

Install the pulley onto the rotor shaft by tightening the pulley nut by hand.
Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque.
Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)

NOTE: Check that SST is secured to the rotor shaft.

Fig 9: Tightening SST 1-B Clockwise
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Mount SST 2 in a vise.
Insert SST 1-A and B into SST 2, and attach the pulley nut to SST 2.

Fig 10: Inserting SST 1-A And B Into SST 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.
Torque: 133 N*m (1351 kgf*cm, 98 ft.*lbf)
Turn SST 1-B, and remove SST 1-A and B.
Turn the pulley and check that the pulley moves smoothly.

Fig 12: Turning Pulley