Charging Systems: Reassembly

Install rotor to drive end frame.
1. Place the rectifier end frame on the pulley.
2. Install the rotor to the rectifier end frame.
Fig 1: Installing Rotor To Drive End Frame
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Install rectifier end frame.
1. Place the generator washer on the rotor.
  
  Fig 2: Placing Generator Washer On Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
  
  Fig 3: Pressing In Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cord clip with the 4 nuts.
  1. Torque:
    1. Nut A: 4.5 N.m (46 kgf.cm, 40 in. lbf)
    2. Nut B: 5.4 N.m (55 kgf.cm, 48 in. lbf)
Fig 4: Identifying Rectifier End Frame Nuts & Cord Clip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install pulley.
1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
2. Hold SST (SST 09820-63010-A) with a torque wrench, and tighten SST (SST 09820-63010-B) clockwise to the specified torque.
  1. Torque: 39 N.m (400 kgf.cm, 29 ft. lbf)
3. Check that SST (SST 09820-63010-A) is secured to the pulley shaft.
  
  Fig 5: Securing SST 09820-63010-A To Pulley Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mount SST (SST 09820-63010-C) in a vise.
5. Insert SST (SST 09820-63010-B) into SST (SST 09820-63010-C), and attach the pulley nut to SST (SST 09820-63010-C).
  
  Fig 6: Attaching Pulley Nut To SST 09820-63010-C
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (SST 09820-63010-A) in the direction shown. See Fig 7.
  1. Torque: 110.5 N.m (1,125 kgf.cm, 81 ft. lbf)
  Fig 7: Tightening Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the generator from SST (SST 09820-63010-C).
8. Turn SST (SST 09820-63010-B), and remove SST (SST 09820-63010-A and SST 09820-63010-B).
Fig 8: Removing SST 09820-63010-A & SST 09820-63010-B
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install rectifier holder.
1. Place the seal plate on the rectifier end frame.
  
  Fig 9: Installing Seal Plate On Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 4 rubber insulators on the lead wires.
3. Install the rectifier holder with the 4 screws.
  1. Torque: 2.9 N.m (30 kgf.cm, 26 in. lbf)
Fig 11: Installing Rectifier Holder
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install voltage regulator and brush holder.
1. Place the voltage regulator and brush holder on the rectifier end frame.
  NOTE: Be careful of the holder installation direction.
  
  Fig 12: Installing Voltage Regulator & Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 5 screws.
  1. Torque: 2.0 N.m (20 kgf.cm, 18 in. lbf)
3. Place the brush holder cover on the brush holder.
Install rear end cover.
1. Install the end cover and plate terminal with the 3 nuts and screw.
  1. Torque:
    1. Screw: 3.9 N.m (39 kgf.cm, 35 in. lbf)
    2. Nut: 4.4 N.m (45 kgf.cm, 39 in. lbf)
  Fig 14: Installing End Cover & Plate Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the terminal insulator with the nut.
  1. Torque: 4.1 N.m (42 kgf.cm, 36 in. lbf)
Fig 15: Installing Terminal Insulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check that rotor rotates smoothly.