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Reassembly [09/2014 - ]: Procedure

  1. INSTALL GENERATOR DRIVE END FRAME BEARING 
    1. Using SST and a press, install a new generator drive end frame bearing.
      GTY509563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00470
      • SST: 09950-70010 
        1. 09951-07100
    2. Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.
      GTY515840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tab
      *b Cutout
    3. Install the 4 screws.

      Torque: 2.3 N.m (23 kgf/cm, 20 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 GENERATOR COIL ASSEMBLY 
    1. Place a new washer on the generator rotor assembly.
    2. Using SST and a press, slowly install in the generator coil assembly.
      GTY499292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09612-70100 
        1. 09612-07240
    3. Install the 4 bolts.
      GTY512160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 1.0 mm (0.0394 in.) pin into the generator brush holder assembly hole.
      GTY434278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin (1.0 mm)
    2. Install the generator brush holder assembly to the generator coil assembly with the 2 screws.
      GTY505171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin (1.0 mm)

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

    3. Pull out the pin from the generator brush holder assembly.
  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 orientation.

  6. INSTALL GENERATOR REAR END COVER 
    1. Install the generator rear end cover to the generator coil assembly with the 3 nuts.
      GTY512161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  7. INSTALL GENERATOR PULLEY WITH CLUTCH 
    1. Secure the generator drive end frame in a vise between aluminum plates.
    2. Temporarily install the generator pulley with clutch to the rotor shaft.
    3. Place the rotor shaft end into SST (A).
      • SST: 09820-63021 
      GTY499917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rotor Shaft
    4. Fit SST (B) to the generator pulley with clutch.
      GTY516120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Pulley with Clutch
    5. Tighten the generator pulley with clutch by turning SST (B) as shown in the illustration.

      Specified tightening torque 

      Torque: 132.5 N.m (1351 kgf/cm, 98 ft.lbf) 

      HINT: 

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

        Refer to PRECAUTION [09/2014 - 11/2017] , or refer to PRECAUTION [11/2017 - ]

      • When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (1.312 ft.)): 106 N.m (1081 kgf/cm, 78 ft.lbf)
      GTY507613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Turn
      *c Hold
    6. Remove SST (A) and (B) from the generator pulley with clutch.
    7. Check that the generator pulley with clutch rotates smoothly.
    8. Remove the generator drive end frame from the vise.
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