2AZ-FE Charging: Generator: Reassembly

INSTALL GENERATOR DRIVE END FRAME BEARING
1. Using SST and a press, press in a new generator drive end frame bearing.
  SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
  
  Fig 1: Pressing Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.
3. Install the 4 screws.
  Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the drive end frame on the clutch pulley.
  
  Fig 2: Identifying Retainer Plate And Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator rotor onto the generator rectifier end frame.
  
  Fig 3: Locating Generator Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place a new generator washer on the generator rotor.
  
  Fig 4: Locating Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Using SST and a press, press in the generator coil assembly to the drive end frame.
  SST 09612-70100 (09612-07240)
  
  Fig 5: Pressing Generator Coil Assembly To Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 6: Locating Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cord clip with the bolt.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
  
  Fig 7: Locating Bolt And Cord Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. While pushing the 2 brushes into the generator brush holder, insert a 1.0 mm (0.039 in.) pin into the generator brush holder.
  
  Fig 8: Inserting Pin Into Generator Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator brush holder with the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
  
  Fig 9: Locating Generator Brush Holder With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pull the pin out of the generator brush holder.
  
  Fig 10: Pulling Pin Out Of Generator Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR TERMINAL INSULATOR
1. Install the terminal insulator onto the generator rectifier end frame.
  
  Fig 11: Locating Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the generator rear end cover with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
INSTALL GENERATOR CLUTCH PULLEY
1. Temporarily install the clutch pulley onto the rotor shaft.
  
  Fig 12: Locating Generator Rear End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set SST (A) and (B).
  SST 09820-63020
3. Clamp SST (A) in a vise.
  
  Fig 13: Setting Rotor Shaft To SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the rotor shaft end into SST (A).
  
  Fig 14: Placing Rotor Shaft End Into SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 15: Fitting SST To Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten the pulley by turning SST (B) in the direction shown in the illustration.
  Torque: 111 N*m (1127 kgf*cm, 82 ft.*lbf)
  
  NOTE: The torque shown above should be used for tightening without using the SST. When the SST is used for tightening, the torque should be calculated based on the length of the SST (See REPAIR INSTRUCTION ).
7. Remove the generator assembly from the SST.
8. Check that the clutch pulley rotates smoothly.
  
  Fig 16: Tightening Pulley By Turning SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Install a new clutch pulley cap to the clutch pulley.