Charging Systems: Generator: Reassembly

INSTALL ROTOR TO DRIVE END FRAME
1. Place the rectifier end frame on the pulley.
2. Install the rotor to the rectifier end frame.
INSTALL RECTIFIER END FRAME
1. Place the generator washer on the rotor.
  
  Fig 2: Installing Rectifier End Frame (1 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
  
  Fig 3: Installing Rectifier End Frame (2 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cord clip with the 4 nuts.
  
  Fig 4: Installing Rectifier End Frame (3 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Torque:
    1. Nut A: 4.5 N.m (46 kgf.cm, 40 in.lbf)
    2. Nut B: 5.4 N.m (55 kgf.cm, 48 in.lbf)
INSTALL PULLEY
1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
2. Check that SST (A) is secured to the pulley shaft.
  
  Fig 5: Using SSTs To Install Generator Pulley (1 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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)
4. Mount SST (C) in a vise.
  
  Fig 6: Using SSTs To Install Generator Pulley (2 Of 4)
  Courtesy 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.
  
  Fig 7: Using SSTs To Install Generator Pulley (3 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 8: Using SSTs To Install Generator Pulley (4 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RECTIFIER HOLDER
1. Place the seal plate on the rectifier end frame.
  
  Fig 9: Installing Rectifier Holder (1 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 4 rubber insulators on the lead wires.
  
  Fig 10: Installing Rectifier Holder (2 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rectifier holder with the 4 screws.
  Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
  
  Fig 11: Installing Rectifier Holder (3 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
1. Place the voltage regulator and brush holder on the rectifier end frame.
  NOTE: Be careful of the holder installation direction.
2. Install the 5 screws.
  Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
  
  Fig 12: Installing Voltage Regulator & Brush Holder (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place the brush holder cover on the brush holder.
  
  Fig 13: Installing Voltage Regulator & Brush Holder (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR END COVER
1. Install the end cover and plate terminal with the 3 nuts and screw.
  1. Torque:
    1. Screw: 3.9 N.m (39 kgf.cm, 35 in.lbf)
    2. Nut: 4.4 N.m (45 kgf.cm, 39 in.lbf)
  Fig 14: Installing Rear End Cover (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the terminal insulator with the nut.
  
  Fig 15: [Installing Rear End Cover (2 Of 2)]
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
CHECK THAT ROTOR ROTATES SMOOTHLY