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Charging Systems: Generator: Reassembly

  1. Place drive end frame on pulley.
  2. Install rotor to drive end frame.
    Fig 1: Placing Drive End Frame On Pulley
    G01132213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Install rectifier end frame
    1. Place the generator washer on the rotor.
      Fig 2: Installing Washer On Rotor
      G01132214Courtesy 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
      G01132215Courtesy 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 Wire Clip
      G01132216Courtesy 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 (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
      1. SST 09820-63011
      2. Torque  : 39 N.m (400 kgf.cm, 29 ft.lbf)
    3. Check that SST (A) is secured to the pulley shaft.
      Fig 5: Tightening Pulley Nut By Hand
      G01132217Courtesy 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. See Fig 6.
      1. Torque  : 110.5 N.m (1,125 kgf.cm, 81 ft.lbf)
        2. Fig 6: Mounting SST In Vise
        G01132218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the generator from SST (C).
    8. Turn SST (B), and remove SST (A and B).
      Fig 7: Removing SST A & B
      G01132219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Install rectifier holder.
    1. Install the 4 rubber insulators on the lead wires.
      Fig 8: Displaying Rubber Insulator Proper Installation
      G01132220Courtesy 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
      G01132221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Install voltage regulator and brush holder.
    1. Place the seal plate on the rectifier end frame.
      Fig 10: Displaying Seal Plate
      G01132222Courtesy 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.
      1. Torque  : 2.0 N.m (20 kgf.cm, 18 in.lbf)
      Fig 11: Locating Screws For Holder Installation
      G01132223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place the brush holder cover on the brush holder.
      Fig 12: Displaying Brush Holder Cover On Brush Holder
      G01132224Courtesy 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)
        Fig 13: Identifying Rear End Cover Bolt, Nuts & Plate Terminal
        G01132225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the terminal insulator with the nut.
      1. Torque  : 6.5 N.m (67 kgf.cm, 58 in.lbf)
  8. Check that rotor rotates smoothly.
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