Charging System - Generators & Regulators: Generator: Reassembly

INSTALL ROTOR TO DRIVE END FRAME
1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
INSTALL RECTIFIER END FRAME
1. Place the generator washer on the rotor.
  
  Fig 2: Installing Rectifier End Frame (1 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
  
  Fig 3: Installing Rectifier End Frame (2 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the wire clip and 4 nuts.
  
  Fig 4: Installing Rectifier End Frame (3 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Torque:
    1. 4.5 N.m (46 kgf.cm, 40 in..lbf) for without wire clip
    2. 5.4 N.m (55 kgf.cm, 48 in..lbf) for with wire clip
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.
  1. SST 09820-63011
  2. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 5: Using SSTs To Install Generator Pulley (1 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mount SST (C) in a vise.
  
  Fig 6: Using SSTs To Install Generator Pulley (2 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
6. To torque the pulley nut, turn SST (A) in the direction shown.
  1. Torque: 111 N.m (1,125 kgf.cm, 81 ft.lbf)
7. Remove the generator from SST (C).
  
  Fig 7: Using SSTs To Install Generator Pulley (3 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn SST (B), and remove SST (A and B).
  
  Fig 8: Using SSTs To Install Generator Pulley (4 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RECTIFIER HOLDER
1. Install the 4 rubber insulators on the lead wires.
  
  Fig 9: Installing Rubber Insulators
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful of the rubber insulators installation direction.
2. Install the rectifier holder while pushing it with the 4 screws
  
  Fig 10: Installing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Torque: 2.9 N.m (30 kgf.cm, 26 in..lbf)
INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
1. Place the seal plate on the rectifier end frame.
  
  Fig 11: Installing Voltage Regulator & Brush Holder (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the voltage regulator and brush holder on the rectifier end frame.
  
  Fig 12: Installing Voltage Regulator & Brush Holder (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful of the holder installation direction.
3. Install the 5 screws.
  1. Torque: 2.0 N.m (20 kgf.cm, 18 in..lbf)
INSTALL REAR END COVER
1. Place the brush holder cover on the brush holder.
  
  Fig 13: Installing Rear End Cover (1 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the end cover and plate terminal with the bolt and 3 nuts.
  
  Fig 14: Installing Rear End Cover (2 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Torque:
    1. 4.4 N.m (45 kgf.cm, 39 in..lbf) for nut
    2. 3.9 N.m (39 kgf.cm, 35 in..lbf) for bolt
3. Install the terminal insulator with the nut.
  1. Torque: 4.1 N.m (42 kgf.cm, 36 in..lbf)
CHECK THAT ROTOR ROTATES SMOOTHLY