Charging System (1ZZ-FE): Generator: Reassembly

1. Place the generator drive end frame on the generator pulley.
2. Install the generator rotor onto the generator drive end frame.
3. Install the generator washer onto the generator rotor.
   Fig 1: Installing Generator Rotor Assembly

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1. Using a socket wrench 29 and a press, slowly push the generator rectifier end frame in.
   Fig 2: Pushing Generator Rectifier End Frame In

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2. Install the generator cord clip and 4 nuts.

   Torque: 

   Nut A 

   4.5 N*m (46 kgf*cm, 40 in.*lbf) 

   Nut B 

   5.4 N*m (55 kg Fern, 48 in.*lbf) 

   Fig 3: Locating Generator Cord Clip And Nuts

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3. Install the 4 terminal insulators onto the generator rectifier end frame.

1. Install the generator holder with rectifier with the 4 screws.

   Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf) 

1. Install the generator regulator with the 3 screws.

   Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) 

1. Install the generator plate seal onto the generator rectifier end frame.
2. Install the generator brush holder with the 2 screws.

   Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) 

   NOTE: Make sure that the generator brush holder is in the correct direction.
   Fig 4: Identifying Protrusion

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3. Install the generator brush cover onto the generator brush holder.
4. Install the generator rear and cover it with the 2 nuts.

   Torque: 4.4 N*m (45 kgf*cm, 39 in.*lbf) 

5. Install the terminal plate.

   Torque: Bolt 

   3.9 N*m (40 kgf*cm, 35 in.*lbf) 

   Nut 

   4.4 N*m (45 kgf*cm, 39 in.*lbf) 

6. Install the terminal insulator with the nut.

   Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf) 

SST 09820-63010 (09820-06010, 09820-06020) 

HINT:

1. Install the generator pulley onto the rotor shaft by tightening the pulley nut by hand.
2. Hold SST 1-A with a torque wrench, then tighten SST 1-B counterclockwise to the specified torque.

   Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

   NOTE: Securely fix SST on the generator rotor shaft.
   Fig 5: Tightening SST 1-B Counterclockwise

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3. Clamp SST 2 in a vise.
   Fig 6: Clamping SST 2 In Vise

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4. Insert SST 1-A and B into SST 2, then attach the pulley nut to SST 2.
5. Tighten the pulley nut, then turn SST 1-A in the direction shown in the illustration.

   Torque: 111 N*m (1,132 kgf*cm, 82 ft.*lbf) 

6. Remove the generator from SST 2.
   Fig 7: Turning SST 1-A

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7. Turn SST 1-B, then remove SST 1-A and B.
8. Turn the generator pulley, then check that the generator pulley moves smoothly.
   Fig 8: Turning Generator Pulley

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