Section 249 (Charging System - Generators & Regulators - 5VZ-FE): Generator: Reassembly

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

Place Rectifier End Frame On Pulley
Install Rotor To Drive End Frame

Fig 1: Installing End Rotor To Drive End Frame
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.
3. Install the 4 nuts.
  1. Torque:
  2. 4.5 N.m (46 kgf.cm, 39 in.lbf)
Fig 3: Using Specified Socket Wrench Press In Rectifier End Frame
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 09820-63011
  1. Torque:
  2. 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 4: Tightening Nut By Hand
  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 5: Locating SST (B) & SST (C) For Attachment
  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. 110.5 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 6: Removing Generator From SST (C)
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 7: Installing Insulators On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier with the 4 screws.
  1. Torque:
  2. 2.94 N.m (30 kgf.cm, 26 in.lbf)
Fig 8: Installing Rectifier With Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Brush Holder And Voltage Regulator
1. Place the seal plate on the rectifier end frame.
  
  Fig 9: Placing Seal Plate On Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the voltage regulator and brush holder on the rectifier end frame.
  NOTE: Be careful of the brush holder installation direction.
3. Install the 5 screws.
  1. Torque:
  2. 1.96 N.m (20 kgf.cm, 17in.lbf)
  Fig 10: Placing Voltage Regulator & Brush Holder On Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the brush holder cover on the brush holder.
Fig 11: Placing Brush Holder Cover On Brush Holder
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. Bolt: 3.85 N.m (39 kgf.cm, 34 in.lbf)
  3. Nut: 4.4 N.m (46 kgf.cm, 39 in.lbf)
  Fig 12: Installing End Cover & Plate Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the terminal insulator with the nut.
  1. Torque:
  2. 4.1 N.m (41.5 kgf.cm, 36 in.lbf)