Section 528 (Charging System): Generator: Reassembly

WARNING: This page is about a different car, the 2005 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL GENERATOR ROTOR
1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
3. Install the generator washer.
  
  Fig 1: Installing Generator Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RECTIFIER END FRAME
1. Using a 21 mm deep socket wrench and press, carefully press in the rectifier end frame.
  
  Fig 2: Installing Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the 4 bolts.
  Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)
  
  Fig 3: Identifying Rectifier End Frame Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 4: Installing Generator Pulley (1 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C) to attach the pulley nut to SST (C).
  
  Fig 5: Installing Generator Pulley (2 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten the pulley nut by turning SST (A) in the direction as shown.
  Torque: 110.3 N.m (1,125 kgf.cm, 81 ft.lbf)
7. Remove the generator from SST (C).
  
  Fig 6: Installing Generator Pulley (3 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn SST (B) and remove SST (A and B).
  
  Fig 7: Installing Generator Pulley (4 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Place the brush holder on the rectifier end frame with the pin facing upward.
10. Install the 2 screws.
  Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf)
  
  Fig 8: Installing Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR END COVER
1. Install the terminal insulator.
  NOTE: Be careful of the insulator's installation direction.
  
  Fig 9: Installing Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the end cover with the 3 nuts.
  Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)
  
  Fig 10: Identifying End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK ROTOR ROTATES ROTATION
Check that the rotor rotates smoothly.