Charging Systems: Generator: Reassembly

INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the drive end frame on the clutch pulley.
2. Install the generator rotor assembly to the drive end frame.
  
  Fig 1: Locating Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place a new generator washer on the generator rotor.
  
  Fig 2: Locating Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Using a deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly.
  
  Fig 3: Pressing Generator Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 4: 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 Ø1.0 mm (0.039 in.) pin into the brush holder hole.
  
  Fig 5: Inserting Pin Into 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)
3. Pull out the pin from the generator brush holder.
  
  Fig 6: Locating Brush Holder Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR TERMINAL INSULATOR
1. Install the terminal insulator to the generator coil.
  NOTE: Pay attention to installation direction of the terminal insulator.
  
  Fig 7: Locating Terminal Insulator
  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 8: Locating End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set SST (A) and (B).
  SST 09820-63020
  
  Fig 9: Setting Rotor Shaft To SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Clamp SST (A) in a vise.
  NOTE: Be sure to fix the flat surface of SST (A) in a vise.
  
  Fig 10: Clamping SST In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the rotor shaft end into SST (A).
  
  Fig 11: Placing Rotor Shaft End Into SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 12: 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 110 N*m (1125 kgf*cm, 81 ft.*lbf) with SST 84 N*m (857 kgf*cm, 62 ft.*lbf)
  NOTE:
  - Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).
  - This torque value is effective when SST is parallel to a torque wrench.
  - Hold the generator assembly tightly.
  Fig 13: Tightening Pulley By Turning 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.