Charging Systems: Generator: 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. 80 A:
  Install the cord clip and 4 nuts.
  
  Fig 4: Installing Cord Strip And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque:
  
  A: 4.5 N.m (46 kgf.cm, 40 in.lbf)
  
  B: 5.4 N.m (55 kgf.cm, 48 in.lbf)
4. 100 A:
  Install the 4 nuts.
  
  Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)
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.
4. As shown in Fig 6, mount SST (C) in a vise, and install the generator to SST (C).
5. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  Torque: 110.5 N.m (1,128 kgf.cm, 81 ft.lbf)
6. Remove the generator from SST (C).
7. Turn SST (B), and remove SST (A and B).
INSTALL RECTIFIER HOLDER
1. Install the 4 rubber insulators on the lead wires.
  
  Fig 7: Installing Rubber Insulators On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier holder while pushing it with the 4 screws.
  
  Fig 8: Installing Rectifier Holder (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 2.94 N.m (30 kgf.cm, 26 in.lbf)
INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
1. Place the seal plate on the rectifier end frame.
  
  Fig 9: 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.
  
  Fig 10: Installing Voltage Regulator And Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  CAUTION: Be careful of the holder installation direction.
3. Install the 5 screws.
  Torque: 2.0 N.m (20 kgf.cm, 17 in.lbf)
4. Place the brush holder cover on the brush holder.
  
  Fig 11: 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 2 nuts and bolt.
  
  Fig 12: Installing End Cover And Plate Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque:
  
  Bolt: 3.8 N.m (39 kgf.cm, 34 in.lbf)
  
  Nut: 4.4 N.m (45 kgf.cm, 39 in.lbf)
2. Install the rear end cover with the 3 nuts.
  
  Fig 13: Installing Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.4 N.m (45 kgf.cm, 39 in.lbf)
3. Install the terminal insulator with the nut.
  
  Fig 14: Installing Terminal Insulator With Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
100 A: INSTALL GENERATOR COVER (CANADA) AND CORD CLIP
1. Canada:
  Install the generator cover with the bolt and nut.
  
  Torque: 16.6 N.m (170 kgf.cm, 12 ft.lbf)
2. Except Canada:
  Install the cord clip with the bolt.
  
  Torque: 16.6 N.m (170 kgf.cm, 12 ft.lbf)
CHECK THAT ROTOR ROTATES SMOOTHLY