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Reassembly [06/2015 - ]: Procedure

  1. INSTALL GENERATOR DRIVE END FRAME BEARING 
    1. Using SST and a press, install a new generator drive end frame bearing.
      GTY489074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00470
      • SST: 09950-70010 
        1. 09951-07100
    2. Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.
      GTY490099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tab
      *b 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 generator drive end frame on the generator pulley with clutch.
    2. Install the generator rotor assembly to the generator drive end frame.
      GTY485201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL GENERATOR COIL ASSEMBLY 
    1. Install a new bearing cover packing.
      GTY493170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Groove
      NOTE:

      Align the protrusions of the bearing cover packing with the grooves of the generator coil assembly when installing.

    2. Using a 21 mm deep socket wrench and press, slowly press in the generator coil assembly.
      GTY487988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 21 mm Deep Socket Wrench
    3. Install the 4 bolts.

      Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) 

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY 
    1. 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.
      GTY483934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin (1.0 mm)
    2. Install the generator brush holder assembly to the generator coil assembly with the 2 screws.
      GTY483539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin (1.0 mm)

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

    3. Pull out the pin from the generator brush holder assembly hole.
  5. 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.

  6. INSTALL GENERATOR REAR END COVER 
    1. Install the generator rear end cover to the generator coil assembly with the 3 bolts.

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

  7. INSTALL GENERATOR PULLEY WITH CLUTCH 
    1. Secure the generator drive end frame in a vise between aluminum plates.
    2. Temporarily install the generator pulley with clutch to the rotor shaft.
    3. Install SST (A) to SST (B) as shown in the illustration.
      • SST: 09820-63021 
      GTY485884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Fit the rotor shaft end into SST (A).
      GTY486366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rotor Shaft
    5. Fit SST (B) to the generator pulley with clutch.
      GTY492380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Turn
      *c Hold
    6. Tighten the generator pulley with clutch by turning SST (B) as shown in the illustration.

      Specified tightening torque 

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

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [06/2015 - ]

      • 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)
    7. Remove SST (A) and (B) from the generator pulley with clutch.
    8. Check that the generator pulley with clutch rotates smoothly.
    9. Remove the generator drive end frame from the vise.
  8. INSTALL GENERATOR PULLEY CAP 
    1. Install a new generator pulley cap to the generator pulley with clutch.
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