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Reassembly [09/2014 - 10/2015]: Procedure

  1. INSTALL GENERATOR ROTOR BEARING 
    1. Using SST and a press, press in a new generator rotor bearing.
      • SST: 09950-60010 
        1. 09951-00470
      • SST: 09950-70010 
        1. 09951-07100
      GTY408023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.
      GTY405103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Tab
      *2 Cutout
    3. Install the 4 screws.

      Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf) 

  2. INSTALL GENERATOR ROTOR ASSEMBLY 
    1. Place the drive end frame on the generator pulley with clutch.
    2. Install the generator rotor to the drive end frame.
    3. Place a new generator washer on the generator rotor.
  3. INSTALL GENERATOR PULLEY WITH CLUTCH 
    1. Temporarily install the generator pulley with clutch onto the rotor shaft.
    2. Mount the drive end frame in a vise tightly.
    3. Confirm SST (A) and (B) shown in the illustration.
      • SST: 09820-63021 
      GTY674467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 SST (A)
      *2 SST (B)
    4. Place the rotor shaft end into SST (A).
      GTY667650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Rotor Shaft
      *2 SST (A)
    5. Fit SST (B) to the generator pulley with clutch.
      GTY614513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Generator Pulley with Clutch
      *2 SST (B)
      *3 SST (A)
    6. Tighten the pulley by turning SST (B) in the direction shown in the illustration.
      GTY617558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      without SST 

      Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 

      with SST 

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

      TEXT IN ILLUSTRATION

      *1 SST (B)
      *2 SST (A)
      *3 Fulcrum Length
      NOTE:
      • Use a torque wrench with a fulcrum length of 400 mm (15.7 in.).
      • This torque value is effective when SST is parallel to the torque wrench.
      • Check that the drive end frame is secured in the vise tightly.
      • Hold SST (A) tightly during the operation.
    7. Remove SST from the generator assembly.
    8. Check that the generator pulley with clutch rotates smoothly.
    9. Install a new generator pulley cap to the generator pulley with clutch.
  4. INSTALL GENERATOR COIL ASSEMBLY 
    1. Using a deep socket wrench (21 mm) and a press, slowly press in the generator coil.
      GTY251098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Deep Socket Wrench (21 mm)
    2. Install the 4 bolts.

      Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) 

  5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY 
    1. While pushing the 2 brushes into the brush holder, insert a 1.0 mm (0.0394 in.) diameter pin into the brush holder hole.
      GTY558490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pin
    2. Install the brush holder to the generator coil with the 2 screws.
      GTY639840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pin

      Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) 

    3. Pull out the pin from the brush holder.
  6. INSTALL GENERATOR TERMINAL INSULATOR 
    1. Install the terminal insulator to the generator coil.
      NOTE:

      Pay attention to the installation direction of the terminal insulator.

  7. INSTALL GENERATOR REAR END COVER 
    1. Install the generator rear end cover to the generator coil with the 3 nuts.

      Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf) 

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