Reassembly [10/2014 - ]: Procedure

INSTALL GENERATOR DRIVE END FRAME BEARING

Using SST and a press, press in a new generator drive end frame bearing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09950-60010
1. 09951-00470
SST: 09950-70010
1. 09951-07100

Fit the tabs on the retainer plate into the cutouts on the generator drive end frame to install the retainer plate.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Tab
*b	Cutout

Install the 4 screws.
Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)

INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the generator drive end frame on the generator pulley with clutch.
2. Install the generator rotor assembly to the generator drive end frame.
3. Install a new washer.

INSTALL GENERATOR COIL ASSEMBLY

Using a 21 mm deep socket wrench and press, slowly press in the generator coil assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Deep Socket Wrench (21 mm)

Install the generator coil assembly with the 4 bolts.
Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)

INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

While pushing the 2 brushes into the generator brush holder assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the brush holder hole.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the generator brush holder assembly to the generator coil assembly with the 2 screws.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)

Pull out the pin from the generator brush holder assembly.

INSTALL GENERATOR TERMINAL INSULATOR
1. Install the generator terminal insulator to the generator coil assembly.
  NOTE:
  Make sure that the terminal insulator is installed with the correct orientation.
INSTALL GENERATOR REAR END COVER
1. Install the generator rear end cover to the generator coil assembly with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)

INSTALL GENERATOR PULLET WITH CLUTCH

Mount the generator assembly in a vise between aluminum plates.
Temporarily install the generator pulley with clutch by hand.

Install SST A and B to the generator pulley with clutch as shown in the illustration.

SST: 09820-63021

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Rotor Shaft

NOTE:

Securely attach SST to the generator pulley with clutch and rotor shaft.

Using a wrench to hold SST A, turn SST B clockwise to tighten the generator pulley with clutch.

Specified tightening torque

Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf)

*a	Hold
*b	Torque Wrench Fulcrum Length
*c	SST Fulcrum Length
	Turn

NOTE:

Be careful as the generator pulley with clutch or rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Refer to PRECAUTION [10/2014 - 09/2017] , or refer to PRECAUTION [09/2017 - 05/2019] , or refer to PRECAUTION [05/2019 - ]
When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (15.8 in.)):
64 N*m (653 kgf*cm, 47 ft.*lbf)

Remove SST from the generator assembly.
Check that the generator pulley with clutch rotates smoothly.
Remove the generator assembly from a vise.

INSTALL GENERATOR PULLEY CAP
1. Install a new generator pulley cap to the generator pulley with clutch.