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Reassembly [10/2015 - ]: Procedure

  1. INSTALL GENERATOR DRIVE END FRAME BEARING 
    1. Using SST and a press, install a new generator drive end frame bearing.
      • SST: 09950-60010 
        1. 09951-00470
      • SST: 09950-70010 
        1. 09951-07100
      GTY685202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.
      GTY667241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tab
      *b Cutout
    3. Install the 4 screws.

      Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) 

  2. INSTALL GENERATOR ROTOR ASSEMBLY 
    1. Place the generator drive end frame on the generator pulley with clutch.
    2. Install the generator rotor assembly to the generator drive end frame.
    3. Install a new generator washer.
  3. INSTALL GENERATOR COIL ASSEMBLY 
    1. Using a 21 mm deep socket wrench and a press, slowly press in the generator coil assembly.
      GTY672602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 21 mm Deep Socket Wrench
    2. Install the generator coil assembly with the 4 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY 
    1. While pushing the 2 brushes into the generator brush holder assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the brush holder hole.
      GTY434278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
    2. Install the generator brush holder assembly to the generator coil assembly with the 2 screws.
      GTY517311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin

      Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) 

    3. Pull out the pin from the generator brush holder assembly hole.
  5. INSTALL GENERATOR TERMINAL INSULATOR 
    1. Install the generator terminal insulator to the generator coil assembly.
      NOTE:

      Be sure to install the generator terminal insulator in the correct direction.

  6. INSTALL GENERATOR REAR END COVER 
    1. Install the generator rear end cover to the generator coil assembly with the 3 nuts.

      Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf) 

  7. INSTALL GENERATOR PULLEY WITH CLUTCH 
    1. Mount the generator assembly in the vise between aluminum plates.
    2. Temporarily install the generator pulley with clutch to the rotor shaft.
    3. Install SST A and B to the generator pulley with clutch as shown in the illustration.
      GTY619862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Generator Rotor Shaft
      • SST: 09820-63021 
      NOTE:

      Securely attach SST to the generator pulley with clutch and generator rotor shaft.

    4. Using a wrench to hold SST A, turn SST B clockwise to tighten the generator pulley with clutch.

      Specified tightening torque 

      Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 

      NOTE:

      Be careful as the generator pulley with clutch or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [10/2015 - ]

      • When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (15.8 in.)):

        64 N*m (653 kgf*cm, 47 ft.*lbf)

      GTY630384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Hold
      *2 Torque Wrench Fulcrum Length
      *3 SST Fulcrum Length
      Turn
    5. Remove SST from the generator assembly.
    6. Check that the generator pulley with clutch rotates smoothly.
    7. Remove the generator assembly from the vise.
  8. INSTALL GENERATOR PULLEY CAP 
    1. Install a new generator pulley cap to the generator pulley with clutch.
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