Reassembly [10/2015 - ]: Procedure

INSTALL GENERATOR DRIVE END FRAME BEARING

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

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

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

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*a	Tab
*b	Cutout

Install the 4 screws.
Torque: 2.95 N*m (30 kgf*cm, 26 in.*lbf)

INSTALL GENERATOR ROTOR ASSEMBLY

Install the generator rotor assembly to the generator drive end frame.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Generator Rotor Assembly
*2	Generator Drive End Frame

INSTALL GENERATOR COIL ASSEMBLY

Place a new washer on the generator rotor assembly.

Temporarily install the generator coil assembly to the generator drive end frame with the 4 through bolts.

NOTE:

Because the generator coil assembly must be installed with a press after the through bolts have first been temporarily tightened, do not attempt to install the generator coil assembly by tightening the through bolts only.

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Using SST and a press, slowly install in the generator coil assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09612-70100
1. 09612-07240

Place the generator assembly on the generator pulley with clutch.
Tighten the 4 through bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Pin (1.0 mm)

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

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*a	Pin (1.0 mm)

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

Install the generator terminal insulator to the generator coil assembly.

NOTE:

Be sure to install the generator terminal insulator in the correct orientation.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL GENERATOR REAR END COVER

Install the generator rear end cover to the generator coil assembly with the 3 nuts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)

INSTALL GENERATOR PULLEY WITH CLUTCH

Secure the generator drive end frame in a vise between aluminum plates.
NOTE:
Do not overtighten the vise.
Temporarily install the generator pulley with clutch to the rotor shaft.

Place the rotor shaft end into SST (A).

SST: 09820-63021
1. 09821-63011

*a	Rotor Shaft

Fit SST (B) to the generator pulley with clutch.

*1	Generator Pulley with Clutch

SST: 09820-63021
1. 09821-63020

Tighten the generator pulley with clutch by turning SST (B) as shown in the illustration.

SST: 09820-63021
1. 09821-63011
2. 09821-63020

Specified tightening torque

Torque: 132.5 N*m (1351 kgf*cm, 98 ft.*lbf)

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Refer to PRECAUTION [10/2015 - ]
When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (1.312 ft.)): 106 N*m (1081 kgf*cm, 78 ft.*lbf)

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

Remove SST (A) and (B).
Check that the generator pulley with clutch rotates smoothly.
Remove the generator drive end frame from the vise.