Charging System (Service Information): Generator: Reassembly: Reassembly

1. Place the generator drive end frame on the generator rotor assembly.
   NOTE:

   Do not drop the generator rotor assembly.

2. Install the generator rotor assembly and the plate retainer.
3. Using a 30 mm socket wrench and press, slowly press in the generator rectifier end frame.
   Fig 1: Pressing Generator Rectifier End Frame

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4. Install the 4 nuts and the cord clip.
   Fig 2: Locating Cord Clip & Nuts

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   Torque: 4.5 N*m (46 kgf*cm, 40 in.*lbf) 

5. Install the 3 terminal insulators onto the generator rectifier end frame.

Fig 3: Locating Generator Holder With Rectifier Screws

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the generator holder with rectifier with the 3 screws.

   Torque: 2.0 N*m (20 kgf*cm, 17 in.*lbf) 

Fig 4: Locating Generator Regulator Assembly Screws

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the generator regulator assembly with the 2 screws.

   Torque: 2.0 N*m (20 kgf*cm, 17 in.*lbf) 

Fig 5: Identifying Generator Brush Holder Assembly

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1. Install the plate seal.
2. Install the generator brush holder assembly with the 3 screws.

   Torque: 2.0 N*m (20 kgf*cm, 17 in.*lbf) 

3. Install the brush cover onto the generator brush holder assembly.
4. Install the rear end cover with the 2 nuts.

   Torque: 4.4 N*m (45 kgf*cm, 39 in.*lbf) 

5. Install the rectifier plate with the nut and screw.

   Torque: 4.4 N*m (45 kgf*cm, 39 in.*lbf) 

   for nut

   Torque: 3.8 N*m (39 kgf*cm, 34 in.*lbf) 

   for bolt

6. Install the terminal insulator with the nut.

   Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf) 

• SST: 09820-63011 
  • 09820-06010
  • 09820-06020

Fig 6: Tightening SST 1-B

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HINT: 

1. Install the generator pulley onto the generator rotor shaft by tightening the generator pulley nut by hand.
2. Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque.

   Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

   NOTE:

   Check that SST is securely fitted onto the generator rotor shaft.

3. Mount SST 2 in a vise.
   Fig 7: Attaching Generator Pulley Nut To SST 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Insert SST 1-A and B into SST 2, and attach the generator pulley nut to SST 2.
5. Tighten the generator pulley nut by turning SST 1-A in the direction shown in the illustration.
   Fig 8: Turning SST 1-A

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 133 N*m (1356 kgf*cm, 98 ft.*lbf) 

6. Remove the generator from SST 2.
7. Turn SST 1-B, and remove SST 1-A and B.
   Fig 9: Turning Generator Pulley

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn the generator pulley, and check that the generator pulley moves smoothly.