Charging Systems: Charging: Generator: Reassembly

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INSTALL ROTOR TO DRIVE END FRAME.
1. Place the rectifier end frame on the pulley.
2. Install the rotor to the rectifier end frame.
INSTALL RECTIFIER END FRAME.
1. Place the generator washer on the rotor.
2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
  
  Fig 2: Pressing In Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cord clip and 3 nuts, and temporarily tighten the 3 nuts.
  
  Fig 3: Locating Rectifier End Frame Nuts & Cord Clip
  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 (SST 09820-63010 A) with a torque wrench, and tighten SST (SST 09820-63010 B) clockwise to the specified torque.
  1. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Check that SST (SST 09820-63010 A) is secured to the pulley shaft.
  
  Fig 4: Securing SST 09820-63010 A To Pulley Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 5: Mounting SST 09820-63010 C In A Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mount SST (SST 09820-63010 C) in a vise.
5. Insert SST (SST 09820-63010 B) into SST (SST 09820-63010 C), and attach the pulley nut to SST (SST 09820-63010 C).
6. To torque the pulley nut, turn SST (SST 09820-63010 A) in the direction shown. See Fig 6
  1. Torque: 110.5 N.m (1,125 kgf.cm, 81 ft.lbf)
7. Remove the generator from SST (SST 09820-63010 C).
8. Turn SST (SST 09820-63010 B), and remove SST (SST 09820-63010 A and SST 09820-63010 B).
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 Rubber Insulators On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier holder while pushing it with the 4 screws.
  1. Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
  Fig 8: Installing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cord clip and nut.
4. Tighten the 4 nuts.
  1. Torque:
    1. Nut A: 4.5 N.m (46 kgf.cm, 40 in.lbf)
    2. Nut B: 5.4 N.m (55 kgf.cm, 48 in.lbf)
INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER.
1. Place the seal plate on the rectifier end frame.
  
  Fig 10: Installing 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.
  
  Fig 11: Placing Voltage Regulator & Brush Holder On Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 5 screws.
  1. Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
INSTALL REAR END COVER.
1. Place the brush holder cover on the brush holder.
  
  Fig 12: Installing Brush Holder Cover On Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the end cover and plate terminal with the bolt and 3 nuts.
  1. Torque:
    1. Nut: 4.4 N.m (45 kgf.cm, 39 in.lbf)
    2. Bolt: 3.8 N.m (39 kgf.cm, 35 in.lbf)
3. Install the terminal insulator with the nut.
  1. Torque: 6.5 N.m (67 kgf.cm, 58 in.lbf)
CHECK THAT ROTOR ROTATES SMOOTHLY.

Fig 13: Installing Rear End Cover & Plate Terminal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002