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: Placing Drive End Frame On Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RECTIFIER END FRAME
1. Place the generator washer on the rotor.
  
  Fig 2: Placing Generator Washer On Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
  
  Fig 3: Installing Rectifier End Frame Using A Socket Wrench And Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the wire clip and 4 nuts.
  Torque:
  
  Nut A: 4.5 Nm (46 kgfcm, 40 in.lbf)
  
  Nut B: 5.4 Nm (55 kgfcm, 48 in.lbf)
  
  Fig 4: Identifying Wire Clip And Nuts
  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 09820-63010
  
  Torque: 39 Nm (400 kgfcm, 29 ftlbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 5: Tightening SST (B) Clockwise Using A Torque Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
  
  Fig 6: Inserting SST (B) 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: 111 Nm (1,125 kgfcm, 81 ftlbf)
7. Remove the generator from SST (C).
  
  Fig 7: Turning SST (A) To Torque Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn SST (B), and remove SST (A and B).
  
  Fig 8: Turning SSTs (A & B) For Removal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RECTIFIER HOLDER
1. Install the 4 rubber insulators on the lead wires.
  NOTE: Be careful of the rubber insulators installation direction.
  
  Fig 9: Installing Rubber Insulators On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier holder while pushing it with the 4 screws
  Torque: 2.9 Nm (30 kgfcm, 26 in.lbf)
Fig 10: Identifying Rectifier Holder Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
1. Place the seal plate on the rectifier end frame.
  
  Fig 11: Placing 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.
3. Install the 5 screws.
  Torque: 2.0 Nm (20 kgfcm, 18 in.lbf)
  
  Fig 12: Installing Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the brush holder cover on the brush holder.
  
  Fig 13: Placing Brush Holder Cover On Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR END COVER
1. Install the end cover and plate terminal with the bolt and 3 nuts.
  Torque:
  
  Nut: 4.4 Nm (45 kgfcm, 39 in.lbf)
  
  Bolt: 3.9 Nm (39 kgfcm, 35 in.lbf)
  
  Fig 14: Installing Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the terminal insulator with the nut.
  Torque: 4.1 Nm (42 kgfcm, 36 in.lbf)
CHECK THAT ROTOR ROTATES SMOOTHLY