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

INSTALL GENERATOR ROTOR BEARING

Fig 1: Pressing Generator Rotor Bearing Into Drive End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, press a new generator rotor bearing into the drive end frame.
  - SST: 09950-60010
    - 09951-00500
  - SST: 09950-70010
    - 09951-07100
2. Align the protrusions of the retainer with the drive end frame's cutouts, and then install the retainer with the 4 screws.
  
  Fig 2: Identifying Retainer With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 3.0 N*m (30 kgf*cm, 27 in.*lbf)
INSTALL GENERATOR ROTOR ASSEMBLY

Fig 3: Locating Generator Rotor Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the generator rotor assembly.
2. Install the generator washer.
  
  Fig 4: Locating Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY

Fig 5: Pressing Generator Coil Into Drive End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, press the generator coil into the drive end frame.
  - SST: 09612-70100
2. Tighten the 4 through bolts.
  
  Fig 6: Locating Generator Through Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

Fig 7: Inserting Pin Into Generator Brush Holder Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Insert a pin (diameter 1.0 mm) into the generator brush holder assembly to fix the 2 brushes in place.
2. Install the generator brush holder to the generator coil with the 2 screws.
  
  Fig 8: Locating Generator Brush Holder Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Remove the pin (diameter 1.0 mm).
INSTALL GENERATOR TERMINAL INSULATOR

Fig 9: Identifying Generator Terminal Insulator To Generator Coil
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the generator terminal insulator to the generator coil.
INSTALL GENERATOR REAR END COVER

Fig 10: Locating Generator Rear End Cover Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the generator rear end cover to the generator coil with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
INSTALL GENERATOR PULLEY
- SST: 09820-63011
  - 09820-06010
  - 09820-06021
Fig 11: Installing Pulley Lock Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the generator pulley, and temporarily install the pulley lock nut.
2. Install SST1-A to the pulley shaft.
3. Install SST1-B to SST1-A.
4. Hold SST 1-A on the pulley shaft area, and tighten SST 1-B to the specified torque.
  Torque: 39.2 N*m (400 kgf*cm, 29 ft.*lbf)
  
  NOTE:
  Securely fix 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.
  
  Fig 12: Mounting Faces Of SST2 In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. With SST1-A and B attached to the generator, insert the pulley lock nut into the hexagon portion of SST2.
7. To tighten the pulley nut, rotate SST1-A in the generator's reverse rotation direction.
  
  Fig 13: Tightening Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 133 N*m (1351 kgf*cm, 98 ft.*lbf)
8. Remove the generator from SST2.
9. Fix SST1-B in place, and rotate SST1-A to the right to loosen it. Then remove SST1-A and B from the generator.
  
  Fig 14: Removing SST1-A And B From Generator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Check that the pulley rotates smoothly.