Charging System: 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 Generator Rotor Assembly
  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 SST and a press, slowly press in the coil assembly.
  SST 09285-76010
  
  Fig 3: Pressing In Coil Assembly Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 4: Installing Generator Rotor 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 09820-63011
  
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 5: Tightening SST (B) Clockwise To Specified Torque
  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: Inserting SST (B) Into SST (C)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown in Fig 7 .
  Torque: 111 N*m (1,125 kgf*cm, 81 ft.*lbf)
  
  Fig 7: Turning SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the generator from SST (C).
8. Turn SST (B), and remove SST (A and B).
  
  Fig 8: Removing SST (A & B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. While pushing the 2 brushes toward the inside of the brush holder, insert a pin ( diameter 1.0 mm (0.039 in.)) into the brush holder hole.
  
  Fig 9: Inserting Pin Into Brush Holder Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator brush holder with the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
  
  Fig 10: Installing Generator Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pull out the pin from the generator brush holder.
INSTALL GENERATOR REAR END COVER
1. Install the terminal insulator to the generator rectifier end frame.
  NOTE: Pay attention the mounting orientation of the terminal insulator.
  
  Fig 11: Identifying 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 12: Installing End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002