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Charging System (2AZ-FE) (Service Information): Generator: Reassembly: Reassembly

  1. 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 Using SST
      GTY292900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        • 09951-00470
      • SST: 09950-70010 
        • 09951-07100
    2. Fit the tabs on the bearing retainer plate into the cutouts on the generator drive end frame to install the generator retainer plate.
      Fig 2: Identifying Retainer Plate And Screw
      GTY162056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 4 screws.

      Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf) 

  2. INSTALL GENERATOR ROTOR ASSEMBLY 
    1. Place the drive end frame on the clutch pulley.
    2. Install the generator rotor onto the generator drive end frame.
      Fig 3: Locating Generator Rotor
      GTY164597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL GENERATOR CLUTCH PULLEY 
    1. Temporarily install the clutch pulley onto the rotor shaft.
    2. Mount the generator drive end frame in a vise tightly.
    3. Confirm SST (A) and (B) shown in the illustration.
      Fig 4: Identifying SST (A) And (B)
      GTY292303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09820-63021 
    4. Place the rotor shaft end into SST (A).
      Fig 5: Placing The Rotor Shaft End Into SST (A)
      GTY291898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Fit SST (B) to the clutch pulley.
      Fig 6: Fitting SST (B) To Clutch Pulley
      GTY291076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the pulley by turning SST (B) in the direction shown in the illustration.
      Fig 7: Tightening Pulley By Turning SST (B)
      GTY290746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      without SST 

      Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 

      with SST 

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

      NOTE:
      • The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.) and a torque wrench with a fulcrum length of 400 mm (1.312 ft.). Refer to PRECAUTION .
      • The "with SST" torque value is effective when SST is parallel to the torque wrench.
      • Check that the drive end frame is secured in the vise tightly.
      • Hold SST (A) tightly during the operation.
    7. Remove SST from the generator assembly.
    8. Check that the clutch pulley rotates smoothly.
    9. Install a new clutch pulley cap to the clutch pulley.
  4. INSTALL GENERATOR COIL ASSEMBLY 
    1. Place a new generator washer on the generator rotor.
      Fig 8: Locating Generator Washer
      GTY185290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, slowly press in the generator coil assembly to the drive end frame.
      Fig 9: Pressing Generator Coil Assembly To Drive End Frame
      GTY161476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09612-70100 
        • 09612-07240
    3. Install the cord clip with the bolt.
      Fig 10: Locating Bolt And Cord Clip
      GTY165405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf) 

    4. Tighten the 4 bolts.
      Fig 11: Locating Bolts
      GTY165422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) 

  5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY 
    1. While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.039 in.) pin into the generator brush holder hole.
      Fig 12: Inserting Pin Into Brush Holder Hole
      GTY219593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the generator brush holder assembly to the generator coil with the 2 screws.
      Fig 13: Locating Generator Brush Holder With Screws
      GTY161477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) 

    3. Pull the pin out of the generator brush holder.
      Fig 14: Pulling Pin Out Of Generator Brush Holder
      GTY165347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL GENERATOR TERMINAL INSULATOR 
    1. Install the terminal insulator to the generator coil.
      Fig 15: Locating Terminal Insulator
      GTY166151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful to the installation direction of the terminal insulator as shown in the illustration.

  7. INSTALL GENERATOR REAR END COVER 
    1. Install the generator rear end cover to the generator coil with the 3 nuts.
      Fig 16: Locating Generator Rear End Cover Nuts
      GTY165970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf) 

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