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Generator ASSY (1ZZ-FE/2ZZ-GE): Replacement

  1. DISCONNECT BATTERY NEGATIVE TERMINAL 
  2. REMOVE CYLINDER HEAD COVER NO.2 (2ZZ-GE ENGINE TYPE) (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  3. REMOVE AIR SWITCHING VALVE ASSY (2ZZ-GE ENGINE TYPE) (See  AIR SWITCHING VALVE ASSY (2ZZ-GE)  ) 
  4. REMOVE ENGINE UNDER COVER RH 
  5. REMOVE FAN AND GENERATOR V BELT 

    HINT:

  6. REMOVE AIR PUMP OUTLET PIPE (2ZZ-GE ENGINE TYPE) 
    1. Disconnect the air hose No. 5.
    2. Remove the 2 bolts, then remove the air pump outlet pipe.
    Fig 1: Removing Air Pump Outlet Pipe
    G02679489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE GENERATOR ASSY 
    1. Remove the wire harness clamp. (2ZZ-GE ENGINE TYPE)
    2. Remove the terminal cap No. 2.
    3. Remove the nut, then remove the generator wire.
    4. Disconnect the generator connector.
    5. Remove the wire harness clamp.
    6. Disconnect the A/C connector.
      Fig 2: Disconnecting Generator Connector And A/C Connector
      G02679490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the bolt, then remove the wire harness clamp bracket. (2ZZ-GE ENGINE TYPE)
      Fig 3: Removing Wire Harness Clamp Bracket
      G02679491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 2 bolts, then remove the generator bracket No. 1. (2ZZ-GE ENGINE TYPE)
      Fig 4: Removing Generator Bracket No 1
      G02679492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 2 bolts, then remove the generator.
      Fig 5: Removing Generator
      G02679493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL GENERATOR ASSY 
    1. Install the generator with the 2 bolts.

      Torque: 

      25 N.m (250 kgf.cm, 18 ft.lbf) for bolt A 

      54 N.m (550 kgf.cm, 40 ft.lbf) for bolt B (1ZZ-FE ENGINE TYPE) 

      58 N.m (590 kgf.cm, 43 ft.lbf) for bolt B (2ZZ-GE ENGINE TYPE) 

      Fig 6: Installing Generator
      G02679494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the wire harness clamp bracket with the bolt. (27.7-GE ENGINE TYPE)

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf ) 

      Fig 7: Installing Wire Harness Clamp Bracket
      G02679495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the A/C connector.
    4. Install the wire harness clamp.
    5. Connect the generator connector.
    6. Install the generator wire with the nut.

      Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) 

    7. Install the terminal cap No. 2.
      Fig 8: Connecting Generator Connector And A/C Connector
      G02679496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the generator bracket No. 1 with the 2 bolts. (2ZZ-GE ENGINE TYPE)

      Torque: 29 N.m (296 kgf.cm, 21 ft.lbf) 

    9. Install the wire harness clamp.
      Fig 9: Installing Generator Bracket No 1
      G02679497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL AIR PUMP OUTLET PIPE (2ZZ-GE ENGINE TYPE) 
    1. Install the air pump outlet pipe with the 2 bolts.

      Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf ) 

    2. Connect the air hose No. 5.
      Fig 10: Installing Air Pump Outlet Pipe
      G02679498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FAN AND GENERATOR V BELT 

    HINT:

  11. INSTALL ENGINE UNDER COVER RH 
  12. INSTALL AIR SWITCHING VALVE ASSY (2ZZ-GE ENGINE TYPE) (See  AIR SWITCHING VALVE ASSY (2ZZ-GE)  ) 
  13. INSTALL CYLINDER HEAD COVER NO.2 (2ZZ-GE ENGINE TYPE) (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  14. CONNECT BATTERY NEGATIVE TERMINAL 

    Torque: 54 N.m (55 kgf.cm, 48 in.lbf ) 

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