Charging System: 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
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INSTALL COIL ASSEMBLY
1. Place the generator washer on the rotor.
  
  Fig 2: Placing Generator Washer On Rotor
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2. Using SST and a press, slowly press in the coil assembly.
  SST 09285-76010
  
  Fig 3: Pressing In Coil Assembly
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3. Install the coil assembly with the 4 bolts.
  Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)
  
  Fig 4: Installing Coil Assembly
  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
  
  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
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4. Mount SST (C) in a vise.
5. Insert SST (A) into SST (C), and attach the pulley nut to SST (C).
  
  Fig 6: Inserting SST (A) Into SST (C)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  Torque: 110.3 N.m (1,125 kgf.cm, 81 ft.lbf)
7. Remove the generator from SST (C).
  
  Fig 7: Tightening Pulley Nut
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8. Turn SST (B), and remove SST (A and B).
  
  Fig 8: Removing SST (A And B)
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9. Place the brush holder on the coil assembly with the pin facing upward.
  NOTE: Be careful of the holder installation direction.
10. Install the 2 screws.
  Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf)
  
  Fig 9: Placing Brush Holder On Coil Assembly With Pin Facing Upward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR END COVER
1. Install the terminal insulator.
  NOTE: Be careful of the terminal insulator installation direction.
  
  Fig 10: Installing Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the end cover with the 3 nuts.
  Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)
CHECK THAT ROTOR ROTATES SMOOTHLY

Fig 11: Installing Rear End Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002