Charging System: Generator: Reassembly

INSTALL ROTOR TO DRIVE END FRAME
1. Place the rectifier end frame on the pulley.
2. install the rotor to the rectifier end frame.
Fig 1: Installing Rotor To Drive End Frame
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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: Identifying Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the wire clip and 4 nuts.
  Torque:
  
  Nut A 4.5 N.m (46 kgf.cm, 40 in..lbf)
  
  Nut B 5.4 N.m (55 kgf.cm, 48 in..lbf)
Fig 4: Installing Wire Clip And Nuts
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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
  
  Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 5: Tightening SST (B) Clockwise
  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: Mounting SST (C) In A Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  Torque: 111 N.m (1,125 kgf.cm, 81 ft.lbf)
7. Remove the generator from SST (C).
  
  Fig 7: Removing Generator From SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn SST (B), and remove SST (A and B).
Fig 8: Removing SST
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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 Rubber Insulators On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier holder while pushing it with the 4 screws
  Torque: 2.9 N.m (30 kgf.cm, 26 in..lbf)
Fig 10: Installing Rectifier Holder
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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.
  Torque: 2.0 N.m (20 kgf.cm, 18 in..lbf)
  
  Fig 12: Installing Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the brush holder cover on the brush holder.
Fig 13: Placing Brush Holder Cover On Brush Holder
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INSTALL REAR END COVER
1. Install the end cover and plate terminal with the bolt and 3 nuts.
  Torque:
  
  Nut 4.4 N.m (45 kgf.cm, 39 in..lbf)
  
  Bolt 3.9 N.m (39 kgf.cm, 35 in..lbf)
  
  Fig 14: Installing End Cover And Plate Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the terminal insulator with the nut.
  Torque: 4.1 N.m (42 kgf.cm, 36 in..lbf)
CHECK THAT ROTOR ROTATES SMOOTHLY

Fig 15: Installing Terminal Insulator With Nut
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