Charging System (Service Information): Generator: Reassembly: Reassembly

INSTALL GENERATOR DRIVE END FRAME BEARING
1. Using SST and a press, press in a new generator drive end frame bearing.
  
  Fig 1: Pressing Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00470
  - SST: 09950-70010
    - 09951-07100
2. Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.
  
  Fig 2: Installing Retainer Plate With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 4 screws.
  Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the drive end frame on the clutch pulley.
2. Install the rotor assembly to the drive end frame.
  
  Fig 3: Identifying Rotor Assembly To Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place a new generator washer on the generator rotor.
  
  Fig 4: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Using SST and a press, press in the generator coil assembly to the drive end frame.
  
  Fig 5: Pressing Generator Coil Assembly To Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09612-70100
    - 09612-07240
2. Install the generator coil assembly with the 4 bolts.
  
  Fig 6: Identifying Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.039 in.) pin into the brush holder hole.
  
  Fig 7: Inserting Pin Into Brush Holder Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator brush holder assembly to the generator coil with the 2 screws.
  
  Fig 8: Installing Generator Brush Holder Assembly To Generator Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Pull out the pin from the generator brush holder.
INSTALL TERMINAL INSULATOR
1. Install the terminal insulator to the generator coil.
  
  Fig 9: Installing Terminal Insulator To Generator Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the generator rear end cover to the generator coil with the 3 nuts.
  
  Fig 10: Identifying Clutch Pulley And Rotor Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
INSTALL CLUTCH PULLEY
1. Temporarily install the clutch pulley onto the rotor shaft.
2. Set SST (A) and (B).
  
  Fig 11: Setting SST (A) And (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09820-63020
3. Clamp SST (A) in a vise.
  
  Fig 12: Placing Rotor Shaft End Into SST (A)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the rotor shaft end into SST (A).
5. Fit SST (B) to the clutch pulley.
  
  Fig 13: Fitting SST (B) To Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten the pulley by turning SST (B) in the direction shown in the illustration.
  
  Fig 14: Identifying Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 111 N*m (1,127 kgf*cm, 81 ft.*lbf)
  
  NOTE:
  The torque shown above should be used for tightening without using SST. When the SST is used for tightening, the torque should be calculated based on the length of the SST. Refer to PRECAUTION .
7. Remove the generator assembly from the SST.
8. Check that the clutch pulley rotates smoothly.
9. Install the new clutch pulley cap to the clutch pulley.