Charging System (Service Information): Generator: Reassembly: Reassembly

INSTALL GENERATOR DRIVE END FRAME BEARING

Fig 1: Installing Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, press in a new bearing.
  - SST: 09950-60010
    1. 09951-00520
  - SST: 09950-70010
    1. 09951-07100
2. Install the bearing retainer with 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 generator pulley.
  
  Fig 3: Installing Generator Rotor To Generator Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator rotor to the generator drive end frame.
3. Place a new washer on the generator rotor.
  
  Fig 4: Placing Washer On Generator Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Using a 21 mm socket wrench and press, slowly press in the generator coil.
  
  Fig 5: Installing Generator Coil Assembly With Deep Socket & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 21 mm Socket Wrench
2. Install the 4 bolts.
  Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)
  
  Fig 6: Locating Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. While pushing the 2 brushes into the generator brush holder, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder.
  
  Fig 7: Identifying Generator Brush Holder, Brushes, Pin & Brush Holder Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Pin
2. Install the generator brush holder with the 2 screws.
  
  Fig 8: Identifying Generator Brush Holder Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
  TEXT IN ILLUSTRATION
  
  *1 Pin
3. Pull the pin out of the generator brush holder.
INSTALL GENERATOR REAR END COVER
1. Install the terminal insulator to the generator coil assembly.
2. Install the generator rear end cover with the 3 nuts.
  Torque: 4.6 N*m (46 kgf*cm, 40 in.*lbf)

INSTALL GENERATOR PULLEY WITH CLUTCH

Temporarily install the generator pulley by hand.
Mount the generator in a vise.
Install SST (A) and (B) to the generator pulley as shown in the illustration.

Fig 9: Installing SST (A) And (B) To Generator Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09820-63021

Using a wrench to hold SST (A), turn SST (B) clockwise to tighten the generator pulley.

Fig 10: Holding SST (A) And Turning SST (B) Clockwise To Tighten Generator Pulley

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)

TEXT IN ILLUSTRATION

*1	Fulcrum Length
*a	Hold
	Turn

HINT:

Use a torque wrench with a fulcrum length of 400 mm (15.7 in.). When using a torque wrench with a fulcrum length that is not 400 mm (15.7 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification. (Refer to PRECAUTION ).
Make sure SST and the wrench are connected in a straight line.

NOTE:

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

Check that the generator pulley rotates smoothly.

INSTALL GENERATOR PULLEY CAP
1. Install a new generator pulley cap to the pulley.
  
  Fig 11: Installing Generator Pulley Cap To Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002