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Charging System - Generators & Regulators - 5VZ-FE: Generator: Reassembly

  1. Place Rectifier End Frame On Pulley 
  2. Install Rotor To Drive End Frame 
    Fig 1: Installing End Rotor To Drive End Frame
    G01092071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Install Rectifier End Frame 
    1. Place the generator washer on the rotor.
      Fig 2: Placing Generator Washer On Rotor
      G01092072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
    3. Install the 4 nuts.
      1. Torque: 
      2. 4.5 N.m (46 kgf.cm, 39 in.lbf) 
    Fig 3: Using Specified Socket Wrench Press In Rectifier End Frame
    G01092073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. 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 4: Tightening Nut By Hand
      G01092074Courtesy 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 5: Locating SST (B) & SST (C) For Attachment
      G01092075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
      1. Torque: 
      2. 110.5 N.m (1,125 kgf.cm, 81 ft.lbf) 
    7. Remove the generator from SST (C).
    8. Turn SST (B), and remove SST (A and B).
    Fig 6: Removing Generator From SST (C)
    G01092076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Install Rectifier Holder 
    1. Install the 4 rubber insulators on the lead wires.
      NOTE: Be careful of the rubber insulators installation direction.
      Fig 7: Installing Insulators On Lead Wires
      G01092077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rectifier with the 4 screws.
      1. Torque: 
      2. 2.94 N.m (30 kgf.cm, 26 in.lbf) 
    Fig 8: Installing Rectifier With Screws
    G01092078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Install Brush Holder And Voltage Regulator 
    1. Place the seal plate on the rectifier end frame.
      Fig 9: Placing Seal Plate On Rectifier End Frame
      G01092079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the voltage regulator and brush holder on the rectifier end frame.
      NOTE: Be careful of the brush holder installation direction.
    3. Install the 5 screws.
      1. Torque: 
      2. 1.96 N.m (20 kgf.cm, 17in.lbf) 
      Fig 10: Placing Voltage Regulator & Brush Holder On Rectifier End Frame
      G01092080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place the brush holder cover on the brush holder.
    Fig 11: Placing Brush Holder Cover On Brush Holder
    G01092081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Install Rear End Cover 
    1. Install the end cover and plate terminal with the bolt and 3 nuts.
      1. Torque: 
      2. Bolt: 3.85 N.m (39 kgf.cm, 34 in.lbf) 
      3. Nut: 4.4 N.m (46 kgf.cm, 39 in.lbf) 
      Fig 12: Installing End Cover & Plate Terminal
      G01092082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the terminal insulator with the nut.
      1. Torque: 
      2. 4.1 N.m (41.5 kgf.cm, 36 in.lbf) 
  8. Check That Rotor Rotates Smoothly 
    Fig 13: Installing Rear End Insulator
    G01092083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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