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Charging Systems: Generator: Reassembly

  1. PLACE DRIVE END FRAME ON PULLEY. 
    Fig 1: Placing Drive End Frame On Pulley
    G03149838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL ROTOR TO DRIVE END FRAME. 
  3. INSTALL RECTIFIER END FRAME 
    1. Place the generator washer on the rotor.
      Fig 2: Placing Generator Washer On Rotor
      G03149839Courtesy 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
      G03149840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 nuts.
      1. Torque:  4.5 N.m (46 kgf.cm, 40 in.lbf)
    4. Install the wire clip with the nut.
      1. Torque:  5.4 N.m (55 kgf.cm, 48 in.lbf)
      Fig 4: Locating Rectifier End Frame Nuts & Wire Clip
      G03149841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. 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
      G03149842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 6: Mounting SST 09820-63010 C In A Vise
      G03149843Courtesy 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).
    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)
        2. Fig 7: Tightening Generator Pulley Nut
        G03149844Courtesy 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).
  5. INSTALL RECTIFIER HOLDER. 
    1. Install the 4 rubber insulators on the lead wires.
      Fig 8: Installing Rubber Insulators On Lead Wires
      G03149845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rectifier holder while pushing it with the 4 screws.
      1. Torque:  2.9 N.m (30 kgf.cm, 26 in.lbf)
      Fig 9: Installing Rectifier Holder
      G03149846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER. 
    1. Place the seal plate on the rectifier end frame.
      Fig 10: Placing Seal Plate On Rectifier End Frame
      G03149847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the voltage regulator and brush holder on the rectifier end frame.
      NOTE: Be careful of the holder installation direction.
      Fig 11: Placing Voltage Regulator & Brush Holder On Rectifier End Frame
      G03149848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 5 screws.
      1. Torque:  2.0 N.m (20 kgf.cm, 18 in.lbf)
    4. Place the brush holder cover on the brush holder.
      Fig 12: Placing Brush Holder Cover On Brush Holder
      G03149849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL REAR END COVER. 
    1. Install the end cover and plate terminal with the bolt and 3 nuts.
      1. Torque: 
        1. Nut:  4.4 N.m (45 kgf.cm, 39 in.lbf)
        2. Bolt:  3.9 N.m (39 kgf.cm, 35 in.lbf)
    2. Install the terminal insulator with the nut.
      1. Torque:  6.5 N.m (67 kgf.cm, 58 in.lbf)
    3. CHECK THAT ROTOR ROTATES SMOOTHLY. 
      Fig 13: Installing Rear End Cover & Plate Terminal
      G03149850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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