Charging System (2ZR-FE): Generator: Reassembly

INSTALL GENERATOR DRIVE END FRAME BEARING
1. Using SST and a press, press in a new generator drive end frame bearing.
  SST 09950-60010 (09951-00470), 09950-70010 (09951-07100)
  
  Fig 1: Pressing Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Fit the tabs of the bearing retainer plate into the cutouts on the generator drive end frame to install the bearing retainer plate.
3. Install the 4 screws.
  Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the drive end frame on the clutch pulley.
  
  Fig 2: Fitting Tabs On Bearing Retainer Plate Into Cutouts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator rotor assembly to the generator drive end frame.
  
  Fig 3: Locating Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place the generator washer on the generator rotor.
  
  Fig 4: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Using SST and a press, slowly press in the generator coil assembly to the drive end frame.
  SST 09612-70100 (09612-07240)
  
  Fig 5: Pressing Generator Coil Assembly To Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 6: Locating Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder hole.
  
  Fig 7: Identifying Pin Into Generator Brush Holder Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the brush holder assembly to the generator coil with the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
  
  Fig 8: Locating Generator Brush Holder Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pull out the pin from the generator brush holder assembly.
  
  Fig 9: Pulling Out Pin From Generator Brush Holder Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR TERMINAL INSULATOR
1. Install the terminal insulator to the generator coil.
  NOTE: Be careful to the installation direction of the terminal insulator as shown in the illustration.
  
  Fig 10: Installing Terminal Insulator To Generator Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the generator rear end cover to the generator coil with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
INSTALL GENERATOR CLUTCH PULLEY
1. Temporarily install the clutch pulley onto the rotor shaft.
  
  Fig 11: Locating Generator Rear End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set SST (A) and (B).
  SST 09820-63021
  
  Fig 12: Setting SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Clamp SST (A) in a vise.
4. Place the rotor shaft end into SST (A).
  
  Fig 13: Placing Rotor Shaft End Into SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 14: Fitting SST To Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten the pulley by turning SST (B) in the direction shown in the illustration.
  Torque: without SST
  
  111 N*m (1127 kgf*cm, 82 ft.*lbf)
  
  with SST
  
  84 N*m (857 kgf*cm, 62 ft.*lbf)
  NOTE:
  - The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.).
  - Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).
  - This torque value is effective when SST is parallel to the torque wrench.
    
    Fig 15: Tightening Pulley By SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the generator assembly from SST.
8. Check that the clutch pulley rotates smoothly.
9. Install a new clutch pulley cap to the clutch pulley.