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Charging Systems: Generator: Reassembly

  1. Place drive end frame on pulley.
    Fig 1: Pressing End Frame On Pulley
    G01179784Courtesy 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
      G01179785Courtesy 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
      G01179786Courtesy 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: Displaying Wire Clip & Nut
      G01179787Courtesy 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.

      SST 09820-63011

      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
      G01179788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mount SST (C) in a vise.
      Fig 6: Mounting SST In Vise
      G01179789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

      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: Removing SST A & B
      G01179790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Install rectifier holder.
    1. Install the 4 rubber insulators on the lead wires.
      Fig 8: Installing Rectifier Holder
      G01179791Courtesy 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: Pushing Rectifier Holder With Screws
      G01179792Courtesy 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
      G01179793Courtesy 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 On Rectifier End Frame
      G01179794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Install rear end cover.
    1. Place the brush holder cover on the brush holder.
      Fig 12: Installing Rear End Cover
      G01179795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the end cover and plate terminal with the bolt and 3 nuts.

      Torque: 

      • 4.4 N.m (45 kgf.cm, 39 in.lbf) for nut
      • 3.9 N.m (39 kgf.cm, 35 in.lbf) for bolt

    3. Install the terminal insulator with the nut.

      Torque  : 6.5 N.m (67 kgf.cm, 58 in.lbf)

  8. Check that rotor rotates smoothly.
    Fig 13: Installing End Cover & Plate Terminal
    G01179796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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