GENERATOR (L3B Type): 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: Installing Pulley & Rotor To Drive End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install rectifier end frame.
1. Place the generator washer on the rotor.
  
  Fig 2: Installing 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.
  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)
  Fig 4: Identifying Retaining Nuts & Cord Clip
  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.
  1. SST 09820-63011
  2. Torque : 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 5: Installing Pulley To Rotor Shaft
  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: 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.
  1. Torque : 110.5 N.m (1125 kgf.cm, 81 ft.lbf)
7. Remove the generator from SST (C).
  
  Fig 7: Displaying SST Turn Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn SST (B), and remove SST (A and B).
Fig 8: Displaying SST (A) & (B)
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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 Insulator On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rectifier holder with the 4 screws.
  1. Torque : 2.9 N.m (30 kgf.cm, 26 in.lbf)
Fig 11: Installing Rectifier Holder
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.
  1. Torque : 2.0 N.m (20 kgf.cm, 18 in.lbf)
  Fig 12: Identifying Voltage Regulator & Bush Holder Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  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: Identifying End Cover Nuts, Screw & Plate Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the terminal insulator with the nut.
  1. Torque : 4.1 N.m (42 kgf.cm, 36 in.lbf)
Check that rotor rotates smoothly.