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Charging Systems: Generator: Reassembly

  1. Install rotor to drive end frame.
    1. Place the rectifier end frame on the pulley.
    2. Install the rotor to the rectifier end frame.
      3. Fig 1: Placing Rectifier End Frame On Pulley
      G01132910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Install rectifier end frame.
    1. Place the generator washer on the rotor.
    2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
      Fig 2: Pressing In Rectifier End Frame
      G01132911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cord clip and 3 nuts, and temporarily tighten the 3 nuts.
      Fig 3: Locating Cord Clip
      G01132912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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 4: Tightening Pulley Nut By Hand
      G01132913Courtesy 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).
      Fig 5: Mounting SST In Vise
      G01132914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
      1. Torque  : 110.5 N.m (1125 kgf.cm, 82 ft.lbf)
    7. Remove the generator from SST (C).
    8. Turn SST (B), and remove SST (A and B).
      Fig 6: Turning SST In Proper Direction
      G01132915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Install rectifier holder.
    1. Install the 4 rubber insulators on the lead wires.
      NOTE: Be careful of the rubber insulators installation direction.
      Fig 7: Installing Rectifier Holder
      G01132916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rectifier holder while pushing it with the 4 screws.
      1. Torque  : 2.94 N.m (30 kgf.cm, 26 in.lbf)
        Fig 8: Pushing Rectifier Holder In With Screws
        G01132917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cord clip and nut.
      Fig 9: Installing Cord Clip & Nut
      G01132918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 4 nuts.
      1. Torque  :
        • 4.5 N.m (46 kgf.cm, 40 in.lbf) for A
        • 5.4 N.m (55 kgf.cm, 48 in.lbf) for B
  5. Install voltage regulator and brush holder.
    1. Place the seal plate on the rectifier end frame.
      Fig 10: Placing Seal Plate To Rectifier End Frame
      G01132919Courtesy 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: Placing Voltage Regulator
      G01132920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Install rear end cover.
    1. Place the brush holder cover on the brush holder.
      Fig 12: Installing Brush Holder Cover
      G01132921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the end cover and plate terminal with the bolt and 3 nuts.
      1. Torque  :
        • 4.4 N.m (45 kgf.cm, 39 in.lbf) for nut
        • 3.8 N.m (39 kgf.cm, 34 in.lbf) for bolt
    3. Install the terminal insulator with the nut.
      1. Torque  : 6.5 N.m (66 kgf.cm, 58 in.lbf)
  7. Check that rotor rotates smoothly.
    Fig 13: Installing End Cover & Plate Terminal
    G01132922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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