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 generator 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 generator drive end frame on the clutch pulley.
2. Install the generator rotor assembly to the generator drive end frame.
  
  Fig 3: Installing Rotor Assembly To Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH PULLEY
1. Temporarily install the clutch pulley onto the rotor shaft.
2. Mount the generator drive end frame in a vise tightly.
3. Confirm SST (A) and (B) shown in the illustration.
  
  Fig 4: Identifying SST (A) And (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09820-63021
4. Place the rotor shaft end into SST (A).
  
  Fig 5: Placing Rotor Shaft Into SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 6: 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 7: Installing Clutch Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  without SST
  
  Torque: 80 N.m (816 kgf cm, 59 ft. lbf)
  
  with SST
  
  Torque: 64 N.m (653 kgf cm, 47 ft. lbf)
  NOTE:
  - The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 400 mm (1.312 ft.).
  - This torque value is effective when SST is parallel to the torque wrench.
  - Hold the generator assembly tightly.
7. Remove SST from the generator assembly.
8. Check that the clutch pulley rotates smoothly.
9. Install a new clutch pulley cap to the clutch pulley.
INSTALL GENERATOR COIL ASSEMBLY
1. Place a new generator washer on the generator rotor.
  
  Fig 8: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the generator coil assembly to the generator drive end frame.
  
  Fig 9: Pressing Generator Coil Assembly To Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09612-70100
    - 09612-07240
3. Install the generator coil assembly with the 4 bolts.
  
  Fig 10: Identifying Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.9 N.m (60 kgf cm, 52 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.) diameter pin into the brush holder hole.
  
  Fig 11: 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 12: Installing Generator Brush Holder Assembly
  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 13: 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 14: Identifying Clutch Pulley & Rotor Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.6 N.m (47 kgf cm, 41 in. lbf)