Charging System: 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.
  
  Fig 1: Placing Rectifier End Frame On Pulley
  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. Install the cord clip with the 4 nuts.
  
  Fig 4: Installing Cord Clip With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque:
  
  Nut A: 4.5 N.m (46 kgf.cm, 40 in.lbf)
  
  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. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
  SST 09820-6301 1
  
  Fig 5: Tightening SST (B) Clockwise To Specified Torque
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Check that SST (A) is secured to the pulley shaft.
4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
  
  Fig 6: Mounting SST In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  
  Fig 7: Removing Generator From SST (C)
  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: Turning SST (B), & Removing SST (A & B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Rectifier 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. Install the 4 rubber insulators on the lead wires.
  
  Fig 10: Installing Rubber Insulators On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rectifier holder with the 4 screws.
  
  Fig 11: Installing Rectifier Holder With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
Install Voltage Regulator And Brush Holder
1. Place the voltage regulator and brush holder on the rectifier end frame.
  
  Fig 12: Install Voltage Regulator & Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful of the holder installation direction.
2. Install the 5 screws.
  Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
3. Place the brush holder cover on the brush holder.
  
  Fig 13: 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 3 nuts and screw.
  
  Fig 14: Installing End Cover & Plate Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque:
  
  Screw: 3.9 N.m (39 kgf.cm, 35 in.lbf)
  
  Nut: 4.4 N.m (45 kgf.cm, 39 in.lbf)
2. Install the terminal insulator with the nut.
  
  Fig 15: Installing Terminal Insulator With Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
Check That Rotor Rotates Smoothly