Charging System: 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 (09951-00470), 09950-70010 (09951-07100)
  
  Fig 1: Installing Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the bearing retainer with the 4 screws.
  Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
INSTALL GENERATOR ROTOR ASSEMBLY
1. Install the generator rotor assembly and generator washer to the drive end frame.
  
  Fig 2: Locating Bearing Retainer And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Using deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly.
  
  Fig 3: Pressing Generator Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 4: Locating Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. While pushing the 2 brushes to the inside of the generator brush holder assembly, insert a 1.0 mm (0.039 in.) pin into the generator brush holder hole.
  
  Fig 5: Identifying Pin Into Generator Brush Holder Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the brush holder assembly with the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Remove the pin from the brush holder assembly.
  
  Fig 6: Locating Pin Of Brush Holder Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TERMINAL INSULATOR
1. Install the terminal insulator.
  NOTE: Pay attention to installation direction of the terminal insulator.
  
  Fig 7: Identifying Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the end cover with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
  
  Fig 8: Locating End Cover With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR WITH CLUTCH PULLEY
1. Set SST (A) and (B).
  SST 09820-63020
  1. Set the rotor shaft to SST (A).
  2. Mount SST (A) in a vise.
    
    Fig 9: Identifying SST (A) And (B)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator with the SST as shown in the illustration.
3. Turn SST (B) counterclockwise, and tighten the generator pulley.
  SST 09820-63020
  
  Torque: 87 N*m (891 kgf*cm, 64 ft.*lbf)
  
  NOTE: Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
  
  Fig 10: Tightening Generator Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the generator from the SST.
  NOTE: Check that the generator pulley rotates smoothly.
5. Install a new generator pulley cap.