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Reassembly [09/2015 - ]: Procedure

  1. INSTALL GENERATOR ROTOR BEARING 
    GTY105245Courtesy 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.
      GTY100851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 3.0 N*m (30 kgf*cm, 27 in.*lbf) 

  2. INSTALL GENERATOR ROTOR ASSEMBLY 
    GTY512157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the generator rotor assembly.
    2. Install the generator washer.
      GTY520725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL GENERATOR COIL ASSEMBLY 
    GTY104457Courtesy 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.
      GTY512160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY 
    GTY656286Courtesy 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.
      GTY635767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Remove the pin (diameter 1.0 mm).
  5. INSTALL GENERATOR TERMINAL INSULATOR 
    GTY105249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the generator terminal insulator to the generator coil.
  6. INSTALL GENERATOR REAR END COVER 
    GTY512161Courtesy 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) 

  7. INSTALL GENERATOR PULLEY 
    • SST: 09820-63011 
      • 09820-06010
      • 09820-06021
    GTY100502Courtesy 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 SST1-B and turn SST1-B counterclockwise with the specified torque.

      Torque: 39.2 N*m (400 kgf*cm, 29 ft.*lbf) 

      NOTE:

      Make sure that SST is secured to the generator rotor shaft.

    5. Mount 2 faces of SST2 in a vise.
      GTY661745Courtesy 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.
      GTY103213Courtesy 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.
      GTY662531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Check that the pulley rotates smoothly.
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