Section 43 (Charging System (Service Information)): Generator: Reassembly: Reassembly

WARNING: This page is about a different car, the 2011 Toyota Avalon. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL GENERATOR DRIVE END FRAME BEARING
1. Using SST and a press, press in a new generator drive end frame bearing.
  
  Fig 1: Installing Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00470
  - SST: 09950-70010
    - 09951-07100
2. Install the bearing retainer with the 4 screws.
  
  Fig 2: Locating Bearing Retainer Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
INSTALL GENERATOR ROTOR ASSEMBLY
1. Install the generator rotor assembly and generator washer to the drive end frame.
INSTALL GENERATOR COIL ASSEMBLY
1. Using deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly.
  
  Fig 3: Pressing In Generator Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 4 bolts.
  
  Fig 4: Locating Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. While pushing the 2 brushes to the inside of the generator brush holder assembly, insert a 1.0 mm (0.039 in.) pin into the generator brush holder hole.
  
  Fig 5: Identifying Pin Into Generator Brush Holder Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the brush holder assembly with the 2 screws.
  
  Fig 6: Locating Brush Holder Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Remove the pin from the brush holder assembly.
INSTALL TERMINAL INSULATOR
1. Install the terminal insulator.
  
  Fig 7: Identifying Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Pay attention to installation direction of the terminal insulator.
INSTALL GENERATOR REAR END COVER
1. Install the end cover with the 3 nuts.
  
  Fig 8: Locating Generator Rear End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
REMOVE GENERATOR WITH CLUTCH PULLEY
1. Set SST (A) and (B).
  
  Fig 9: Setting SST (A) And (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09820-63020
  1. Set the rotor shaft to SST (A).
  2. Mount SST (A) in a vise.
2. Install the generator with the SST as shown in the illustration.
  
  Fig 10: Tightening Generator Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn SST (B) counterclockwise, and tighten the generator pulley.
  - SST: 09820-63020
  Torque: 87 N*m (891 kgf*cm, 64 ft.*lbf)
  
  NOTE:
  Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
4. Remove the generator from the SST.
  NOTE:
  Check that the generator pulley rotates smoothly.
5. Install a new generator pulley cap.