Charging Systems: Charging: Reassembly

PLACE DRIVE END FRAME ON PULLEY
INSTALL ROTOR TO DRIVE END FRAME

Fig 1: Installing Rotor To Drive End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 3 nuts.
  Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)
4. Install the wire clip with the nut.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
Fig 4: Installing Wire Clip With Nut
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 (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
  SST 09820-63010
  
  Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 5: Installing Pulley To Rotor Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  
  Fig 6: Torquing Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 110.5 N.m (1,125 kgf.cm, 81 ft.lbf)
7. Remove the generator from SST (C).
8. Turn SST (B), and remove SST (A and B).
Fig 7: Turning SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RECTIFIER HOLDER
1. Install the 4 rubber insulators on the lead wires.
  
  Fig 8: Installing Rubber Insulators On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier holder while pushing it with the 4 screws.
  Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
  
  Fig 9: Installing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy 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.
3. Install the 5 screws.
  Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
  
  Fig 11: Placing Voltage Regulator And Brush Holder On Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the brush holder cover on the brush holder.
Fig 12: Placing Brush Holder Cover On Brush Holder
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR END COVER
1. Install the end cover and plate terminal with the bolt and 3 nuts.
  Torque:
  
  Nut 4.4 N.m (45 kgf.cm, 39 in.lbf)
  
  Bolt 3.9 N.m (39 kgf.cm, 35 in.lbf)
2. Install the terminal insulator with the nut.
  Torque: 6.5 N.m (67 kgf.cm, 58 in.lbf)
CHECK THAT ROTOR ROTATES SMOOTHLY

Fig 13: Installing Terminal Insulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002