Charging System - Generators & Regulators: Generator: Reassembly

Install Rotor To Drive End Frame
1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
Fig 1: Installing 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: Placing 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: Pressing In Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the wire clip and 4 nuts.
  1. Torque:
  2. Nut A 4.5 N.m (46 kgf.cm, 40 in.lbf)
  3. Nut B 5.4 N.m (55 kgf.cm, 48 in.lbf)
Fig 4: Installing Wire Clip & 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 09820-63011
  1. Torque:
  2. 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: Locating SST (C) For Attachment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  1. Torque:
  2. 111 N.m (1,125 kgf.cm, 81 ft.lbf)
7. Remove the generator from SST (C).
  
  Fig 7: Displaying How To Remove Generator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn SST (B), and remove SST (A and B).
  
  Fig 8: Removing SST (A & B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Rectifier Holder
1. Install the 4 rubber insulators on the lead wires.
  NOTE: Be careful of the rubber insulators installation direction.
  
  Fig 9: Installing Insulator On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier holder while pushing it with the 4 screws
  1. Torque:
  2. 2.9 N.m (30 kgf.cm, 26 in.lbf)
Fig 10: Installing Rectifier Holder With Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Voltage Regulator And Brush Holder
1. Place the seal plate on the rectifier end frame.
  
  Fig 11: Placing Seal Plate On Rectifier End 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.
  1. Torque:
  2. 2.0 N.m (20 kgf.cm, 18 in.lbf)
  Fig 12: Displaying Proper Installation Of Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the brush holder cover on the brush holder.
  
  Fig 13: Displaying Brush Holder On 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.
  1. Torque:
  2. Nut 4.4 N.m (45 kgf.cm, 39 in.lbf)
  3. Bolt 3.9 N.m (39 kgf.cm, 35 in.lbf)
2. Install the terminal insulator with the nut.
  1. Torque:
  2. 4.1 N.m (42 kgf.cm, 36 in.lbf)
    
    Fig 14: Installing End Cover & Plate Terminal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check That Rotor Rotates Smoothly