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 Using SST & Press
  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 (A)
  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: Placing Generator Washer On Generator Rotor
  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 Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09612-70100
    - 09612-07240
3. Install the generator coil assembly with the 4 bolts.
  
  Fig 10: Installing 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 And Rotor Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)