Section 272 (Charging System - Generators & Regulators): Generator: Reassembly

WARNING: This page is about a different car, the 2002 Toyota MR2. However, it is still accessible from the selected car via links, so may be relevant.

Install Rotor To Drive End Frame
1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
  
  Fig 1: Placing Drive End Frame On Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Rectifier End Frame
1. Place the generator washer on the rotor.
  
  Fig 2: Placing Generator Washer On Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
  
  Fig 3: Pressing In Rectifier End Frame Using Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the wire clip and 4 nuts.
  1. Torque:
  2. Nut A: 4.5 N.m (46 kgf.cm, 40 in.lbf)
  3. Nut B: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  Fig 4: Installing Wire Clips & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Pulley
1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
2. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
  SST 09820-63010
  1. Torque:
  2. 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 5: Displaying Pulley Installation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
  
  Fig 6: Mounting SST In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  1. Torque:
  2. 111 N.m (1,125 kgf.cm, 81 ft.lbf)
7. Remove the generator from SST (C).
8. Turn SST (B), and remove SST (A and B).
  
  Fig 8: Removing SST (A & B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Rectifier Holder
1. Install the 4 rubber insulators on the lead wires.
  NOTE: Be careful of the rubber insulators installation direction.
  
  Fig 9: Installing Rubber Insulators
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier holder while pushing it with the 4 screws
  1. Torque:
  2. 2.9 N.m (30 kgf.cm, 26 in.lbf)
  Fig 10: Installing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Voltage Regulator And Brush Holder
1. Place the seal plate on the rectifier end frame.
  
  Fig 11: Placing Seal Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the voltage regulator and brush holder on the rectifier end frame.
  NOTE: Be careful of the holder installation direction.
3. Install the 5 screws.
  1. Torque:
  2. 2.0 N.m (20 kgf.cm, 18 in.lbf)
  Fig 12: Placing Voltage Regulator Correctly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the brush holder cover on the brush holder.
  
  Fig 13: Placing Brush Holder Cover On Appropriate Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Rear End Cover
1. Install the end cover and plate terminal with the bolt and 3 nuts.
  1. Torque:
  2. Nut: 4.4 N.m (45 kgf.cm, 39 in.lbf)
  3. Bolt: 3.9 N.m (39 kgf.cm, 35 in.lbf)
2. Install the terminal insulator with the nut.
  1. Torque:
  2. 4.1 N.m (42 kgf.cm, 36 in.lbf)

Fig 14: Placing Brush Holder

Check That Rotor Rotates Smoothly