Reassembly [12/2017 - ]: Procedure

INSTALL GENERATOR DRIVE END FRAME BEARING

Using SST and a press, install a new generator drive end frame bearing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09950-60011
1. 09951-00470
SST: 09950-70010
1. 09951-07100

Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Tab
*b	Cutout

Install the 4 screws.
Torque: 2.95 N.m (30 kgf/cm, 26 in.lbf)

INSTALL GENERATOR ROTOR ASSEMBLY

Install the generator rotor assembly to the generator drive end frame.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Generator Rotor Assembly
*2	Generator Drive End Frame

Place a new washer on the generator rotor assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Cutout

NOTE:

Make sure to install the washer so that its cutout faces the bearing side, as the washer must be installed in a specific direction.

INSTALL GENERATOR COIL ASSEMBLY

Temporarily install the generator coil assembly to the generator drive end frame with the 4 through bolts.
NOTE:
Because the generator coil assembly must be installed with a press after the through bolts have first been temporarily tightened, do not attempt to install the generator coil assembly by tightening the through bolts only.

Using SST and a press, slowly install in the generator coil assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09612-70100
1. 09612-07240

Place the generator assembly on the generator pulley with clutch.
Tighten the 4 through bolts.
Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf)

INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder assembly hole.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Pin (1.0 mm)

Install the generator brush holder assembly to the generator coil assembly with the 2 screws.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Pin (1.0 mm)

Torque: 1.76 N.m (18 kgf/cm, 16 in.lbf)

Pull out the pin from the generator brush holder assembly.

INSTALL GENERATOR TERMINAL INSULATOR
1. Install the generator terminal insulator to the generator coil assembly.
  NOTE:
  Be sure to install the generator terminal insulator in the correct orientation.
INSTALL GENERATOR REAR END COVER
1. Install the generator rear end cover to the generator coil assembly with the 3 nuts.
  Torque: 4.55 N.m (46 kgf/cm, 40 in.lbf)

INSTALL GENERATOR PULLEY WITH CLUTCH

Secure the generator drive end frame in a vise between aluminum plates.
NOTE:
Do not overtighten the vise.
Temporarily install the generator pulley with clutch to the generator rotor shaft.

Install SST A and SST B to the generator pulley with clutch as shown in the illustration.

SST: 09820-63021

*a	Generator Rotor Shaft

NOTE:

Securely attach SST to the generator pulley with clutch and generator rotor shaft.

Using a wrench to hold SST A and turn SST B clockwise to tighten the generator pulley with clutch.

Specified tightening torque

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

NOTE:

Be careful as the generator pulley with clutch or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Refer to PRECAUTION [12/2017 - 10/2020] , or refer to PRECAUTION [10/2020 - 10/2023] , or refer to PRECAUTION [10/2023 - ]
When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (1.312 ft.)): 64 N.m (653 kgf/cm, 47 ft.lbf)

*a	Torque Wrench Fulcrum Length
*b	SST Fulcrum Length
*c	Hold
	Turn

Remove SST from the generator assembly.
Check that the generator pulley with clutch rotates smoothly.
Remove the generator drive end frame from the vise.

INSTALL GENERATOR PULLEY CAP
1. Install a new generator pulley cap to the generator pulley with clutch.