Charging Systems: Charging: Generator: Reassembly

INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
  
  Fig 1: Installing Rotor To Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
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 coil.
  
  Fig 3: Pressing Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the coil with the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 4: Locating Coil With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR 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 09820-63010
  
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 5: Installing Generator Pulley
  Courtesy 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 6: Attaching Pulley Nut To SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To tighten the pulley nut, turn SST (A) in the direction shown in the illustration.
  Torque: 111 N*m (1,132 kgf*cm, 82 ft.*lbf)
7. Remove the generator from SST (C).
  
  Fig 7: Removing Generator From SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn SST (B) and remove SST (A and B).
  
  Fig 8: Turning Generator From SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. Place the front seal plate onto the coil.
  
  Fig 9: Placing Front Seal Plate Onto Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the brush holder on the coil.
  NOTE: Be careful of the holder's installation direction.
3. Install the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
4. Place the rear seal plate on the brush holder.
  
  Fig 10: Placing Rear Seal Plate On Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the terminal insulator.
2. Install the end cover with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
CHECK THAT ROTOR ROTATES SMOOTHLY

Fig 11: Locating End Cover With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002