Reassembly [09/2015 - 12/2017]: Procedure

INSTALL GENERATOR DRIVE END FRAME BEARING

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

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Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.

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*a	Tab
*b	Cutout

Using a T20 "TORX" socket wrench, install the 4 screws.
Torque: 3.5 N.m (36 kgf/cm, 31 in.lbf)

INSTALL GENERATOR ROTOR ASSEMBLY

Place the generator drive end frame on the generator pulley with clutch.

Install the generator rotor assembly to the generator drive end frame.

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*1	Generator Rotor Assembly
*2	Generator Drive End Frame

Install the generator coil assembly with the 4 bolts.

Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf)

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INSTALL GENERATOR REGULATOR ASSEMBLY

While pushing the 2 brushes into the generator regulator assembly, insert a 1.0 mm (0.0394 in.) pin into the generator regulator assembly as shown in the illustration.

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*a	Pin (1.0 mm)

Push down the generator regulator assembly cover and secure the 2 brushes as shown in the illustration.

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*a	Pin (1.0 mm)
	Brush
	Generator Regulator Assembly Cover
	Push down
	Pull out

Pull out the pin from the generator regulator assembly.

Install the generator regulator assembly to the generator coil assembly with the 2 bolts and stud bolt.

Torque: 4.3 N.m (44 kgf/cm, 38 in.lbf)

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*a	Bolt
*b	Stud Bolt

Push in the generator regulator assembly cover as shown in the illustration.

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Push in

INSTALL GENERATOR REAR END COVER

Install the generator rear end cover to the generator assembly with the 2 nuts.

Torque: 3.3 N.m (34 kgf/cm, 29 in.lbf)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL GENERATOR PULLEY WITH CLUTCH

Secure the generator assembly in a vise between aluminum plates.
Temporarily install the generator pulley with clutch to the rotor shaft.

Fit SST to the generator pulley with clutch.

*1	Generator Pulley with Clutch

SST: 09820-30010

Fit a T50 "TORX" socket wrench into the rotor shaft end.

*a	Rotor Shaft
*b	T50 "TORX" Socket Wrench

Tighten the generator pulley with clutch by turning SST as shown in the illustration.

Specified tightening torque

Torque: 78.5 N.m (800 kgf/cm, 58 ft.lbf)

NOTE:

Check that the generator assembly is secured in the vise tightly.
Hold the T50 "TORX" socket wrench tightly during the operation.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Refer to PRECAUTION [09/2015 - 12/2017]
When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 400 mm (1.312 ft.)): 73 N.m (744 kgf/cm, 54 ft.lbf)

*a	Torque Wrench Fulcrum Length
*b	T50 "TORX" Socket Wrench
*c	Turn
*d	Hold

Remove SST and the T50 "TORX" socket wrench from the generator pulley with clutch.
Check that the generator pulley with clutch rotates smoothly.
Remove the generator assembly from the vise.

INSTALL GENERATOR PULLEY CAP
1. Install a new generator pulley cap to the generator pulley with clutch.