Charging (4GR-FSE): Generator: Reassembly

1. Using SST and a press, press in a new generator drive end frame bearing.
   Fig 1: Pressing Generator Drive End Frame Bearing Using SST & Press

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   SST 09950-60010 (09951-00470), 09950-70010 (09951-07100) 

2. Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.
3. Install the 4 screws.

Fig 2: Installing Retainer Plate With Screws

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Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf) 

1. Place the drive end frame on the clutch pulley.
2. Install the rotor assembly to the drive end frame.
   Fig 3: Installing Rotor Assembly To Drive End Frame

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3. Place a new generator washer on the generator rotor.

Fig 4: Placing Generator Washer On Generator Rotor

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1. Using SST and a press, press in the generator coil assembly to the drive end frame.
   Fig 5: Pressing Generator Coil Assembly To Drive End Frame Using SST & Press

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   SST 09612-70100 (09612-07240) 

2. Install the generator coil assembly with the 4 bolts.

Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) 

Fig 6: Installing Generator Coil Assembly Bolts

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1. While pushing the 2 brushes into the generator brush holder assembly, insert a $$ 1.0 mm (0.039 in.) pin into the brush holder hole.
   Fig 7: Inserting Pin Into Brush Holder Hole

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2. Install the generator brush holder assembly to the generator coil with the 2 screws.
   Fig 8: Installing Generator Brush Holder Assembly To Generator Coil

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   Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) 

3. Pull out the pin from the generator brush holder.

1. Install the terminal insulator to the generator coil.

Fig 9: Installing Terminal Insulator To Generator Coil

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1. Install the generator rear end cover to the generator coil with the 3 nuts.

Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf) 

Fig 10: Installing Generator Rear End Cover Nuts

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1. Temporarily install the clutch pulley onto the rotor shaft.
2. Set SST (A) and (B).

   SST 09820-63020 

   Fig 11: Setting SST (A) & (B)

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3. Clamp SST (A) in a vise.
4. Place the rotor shaft end into SST (A).
   Fig 12: Placing Rotor Shaft End Into SST (A)

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5. Fit SST (B) to the clutch pulley.
   Fig 13: Fitting SST (B) To Clutch Pulley

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6. Tighten the pulley by turning SST (B) in the direction shown in Fig 14 .
   Fig 14: Tightening Pulley By Turning SST (B)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 111 N*m (1,127 kgf*cm, 81 ft.*lbf) 

   NOTE: The torque shown above should be used for tightening without using SST. When the SST is used for tightening, the torque should be calculated based on the length of the SST (See REPAIR INSTRUCTION ).
7. Remove the generator assembly from the SST.
8. Check that the clutch pulley rotates smoothly.
9. Install the new clutch pulley cap to the clutch pulley.