Charging (2JZ-GE): Generator: Reassembly

PLACE DRIVE END FRAME ON PULLEY
INSTALL ROTOR TO DRIVE END FRAME

Fig 1: Placing Drive End Frame On Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RECTIFIER END FRAME
1. Place the generator washer on the rotor.
  
  Fig 2: Installing 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: Installing Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 3 nuts.
  Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)
4. Install the wire clip with the nut.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  
  Fig 4: Installing Wire Clips With Nuts
  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 09820-6301 1
  
  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).
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  Torque: 110.5 N.m (1,125 kgf.cm, 81 ft.lbf)
  
  Fig 6: Tightening Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the generator from SST (C).
8. Turn SST (B), and remove SST (A and B).
  
  Fig 7: Remove SST From Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RECTIFIER HOLDER
1. Install the 4 rubber insulators on the lead wires.
  
  Fig 8: Installing Rubber Insulators
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier holder while pushing it with the 4 screws.
  Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
  
  Fig 9: Installing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
1. Place the seal plate on the rectifier end frame.
  
  Fig 10: Installing Seal Plate On Rectifier And Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the voltage regulator and brush holder on the rectifier end frame.
  NOTE: Be careful of the holder installation direction.
3. Install the 5 screws.
  Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
  
  Fig 11: Holder On Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the brush holder cover on the brush holder.
  
  Fig 12: Installing Brush Holder Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR END COVER
1. Install the end cover and plate terminal with the bolt and 3 nuts.
  Torque:
  
  Nut 4.4 N.m (45 kgf.cm, 39 in.lbf)
  
  Bolt 3.9 N.m (39 kgf.cm, 35 in.lbf)
  
  Fig 13: Installing Rear End Cover & Plate Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the terminal insulator with the nut.
  Torque: 6.5 N.m (67 kgf.cm, 58 in.lbf)
CHECK THAT ROTOR ROTATES SMOOTHLY