Section 378 (Charging System - Generators & Regulators): Generator: Reassembly

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

Install Rotor To Drive End Frame
1. Place the rectifier end frame on the pulley.
2. Install the rotor to the rectifier end frame.
Install Rectifier End Frame
1. Place the thrust washer on the rotor.
2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
  
  Fig 3: Using Socket Wrench To Press In Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. NUT A:
  1. Install the cord clip and 4 nuts.
  2. Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)
4. NUT B:
  1. Install the cord clip and 4 nuts.
  2. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  Fig 4: Installing Cord Clip & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the wire clamp.
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
  
  Fig 5: Using SSTs To Install Pulley (1 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Check that SST (A) is secured to the pulley shaft.
4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
  
  Fig 6: Using SSTs To Install Pulley (2 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  
  Fig 7: Using SSTs To Install Pulley (3 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 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 8: Using SSTs To Install Pulley (4 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Rectifier Holder
1. Place the seal plate on the rectifier end frame.
  
  Fig 9: Installing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 4 rubber insulators on the lead wires.
  
  Fig 10: Installing Rubber Insulators On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rectifier holder with the 4 screws.
  
  Fig 11: Installing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
Install Voltage Regulator And Brush Holder
1. Place the voltage regulator and brush holder on the rectifier end frame.
  NOTE: Be careful of the holder installation direction.
2. Install the 5 screws.
  Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
3. Place the brush holder cover on the brush holder.
  
  Fig 13: Installing Brush Holder Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Rear End Cover
1. Install the end cover and plate terminal with the 3 nuts and screw.
  
  Fig 14: Installing End Cover & Plate Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Torque:
  2. Screw: 3.9 N.m (39 kgf.cm, 35 in.lbf)
  3. Nut: 4.4 N.m (45 kgf.cm, 39 in.lbf)
2. Install the terminal insulator with the nut.
  
  Fig 15: Installing Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.1 N.m (41.5 kgf.cm, 36 in.lbf)
Check That Rotor Rotates Smoothly