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

INSTALL GENERATOR DRIVE END FRAME BEARING

Using SST and a press, press in a new generator drive end frame bearing.

Fig 1: Identifying SST & Generator Drive End Frame Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09950-60010
  1. 09951-00470
- SST: 09950-70010
  1. 09951-07100

Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.

Fig 2: Identifying Retainer Plate, Drive End Frame, Retainer Plate & Tabs

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Tab
*2	Cutout

Install the 4 screws.
Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)

INSTALL GENERATOR ROTOR ASSEMBLY
1. Install the generator rotor assembly to the drive end frame.
2. Place the generator washer on the generator rotor.
INSTALL GENERATOR COIL ASSEMBLY
1. Using a deep socket wrench (21 mm) and press, slowly press in the generator coil assembly.
  
  Fig 3: Identifying Generator Coil Assembly & Deep Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Deep socket wrench (21 mm)
2. Install the 4 bolts.
  Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. While pushing the 2 brushes into the generator brush holder, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the brush holder hole.
  
  Fig 4: Identifying Generator Brush Holder, Brushes, Pin & Brush Holder Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Pin
2. Install the generator brush holder to the generator coil with the 2 screws.
  
  Fig 5: Identifying Generator Brush Holder, Generator Coil & Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Pin
  
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Pull out the pin from the generator brush holder.
INSTALL GENERATOR TERMINAL INSULATOR
1. Install the terminal insulator to the generator coil.
  
  Fig 6: Identifying Generator Terminal Insulator & Generator Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Pay attention to installation direction of the terminal insulator.
INSTALL GENERATOR REAR END COVER
1. Install the generator rear end cover to the generator coil with the 3 nuts.
  
  Fig 7: Identifying Nuts And Generator Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.6 N*m (46 kgf*cm, 40 in.*lbf)
2. Install the cord clamp with the nut.
  
  Fig 8: Locating Nut And Cord Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf)

INSTALL GENERATOR CLUTCH PULLEY

Temporarily install the generator with clutch pulley by hand.
Mount the generator in a vise between aluminum plates.
Install SST (A) and (B) to the generator with clutch pulley as shown in the illustration.

Fig 9: View of Generator Clutch Pulley Using SST (A & B)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION

*1 Rotor Shaft
- SST: 09820-63021
NOTE:
Securely attach SST to the generator with clutch pulley and generator rotor shaft.

Using a wrench to hold SST (A), turn SST (B) clockwise to tighten the generator with clutch pulley.

Fig 10: Identifying SST (A & B), Generator Clutch Pulley, Generator Rotor Shaft & Wrench

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Hold
	Turn

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:

Be careful as the generator with clutch pulley or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.
Use a torque wrench with a fulcrum length of 400 mm (15.7 in.).
The torque value for use with SST is effective when SST is parallel to the torque wrench.

Remove SST from the generator.
Check that the generator with clutch pulley rotates smoothly.

INSTALL GENERATOR PULLEY CAP
1. Install a new clutch pulley cap to the clutch pulley.