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Charging System - Generators & Regulators: Generator: Reassembly

  1. PLACE RECTIFIER END FRAME ON PULLEY 
    Fig 1: Placing Rectifier End On Pulley
    G01025102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL ROTOR TO DRIVE END FRAME 
  3. INSTALL RECTIFIER END FRAME 
    1. Install the generator washer to the rectifier end frame.
      NOTE: Be careful of the generator washer installation direction.
    2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
      Fig 2: Using 29mm Socket Wrench & Press To Push In Rectifier
      G01025103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 4 nuts.
      1. Torque: 4.5 N.m (45 kgf.cm, 39 in..lbf) 
  4. 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.
      Fig 3: Tightening SST To Clockwise To Specific Torque
      G01025104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09820-63011
      2. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
    3. Check that SST (A) is secured to the pulley shaft.
    4. As shown in the illustration, mount SST (C) in a vise, and install the generator with SST (A) and (B) to SST (C).
    5. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
      1. Torque: 110 N.m (1,125 kgf.cm, 81 ft.lbf) 
    6. Remove the generator with SST (A) and (B) from SST (C).
    7. Turn SST (B) and remove SST (A) and (B).
  5. INSTALL RECTIFIER HOLDER 
    1. Install the 4 rubber insulators on the lead wires.
    2. Install the rectifier with the 4 screws.
      1. Torque: 2.0 N.m (20 kgf.cm, 18 in..lbf) 
    Fig 4: Using SST To Torque Pulley Nut To Specified Value
    G01025105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL BRUSH HOLDER AND VOLTAGE REGULATOR 
    1. Place the brush holder cover to the brush holder.
      Fig 5: Installing Brush Holder & Voltage Regulator
      G01025106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the voltage regulator and brush holder to the rear end frame horizontally as shown in the illustration.

      HINT:

      Check that the brush holder's cover doesn't slip to one side during installation.

    3. Tighten the 5 screws until there is a clearance of at least 1 mm (0.04 in.) between the brush holder cover and connector.
      Fig 6: Installing Five Screws Until Clearance Is At Least 1 mm (0.04)
      G01025107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL REAR END COVER 
    1. Install the end cover with the 3 nuts.
      1. Torque: 4.5 N.m (45 kgf.cm, 39 in..lbf) 
    2. Install the terminal insulator with the nut.
      1. Torque: 4.1 N.m (42 kgf.cm, 36 in..lbf) 
  8. MAKE SURE ROTOR ROTATES SMOOTHLY 
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