Reassembly [10/2017 - ]: Procedure

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INSTALL GENERATOR DRIVE END FRAME BEARING

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

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fit the tabs of the retainer plate into the cutouts of 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 generator washer.

INSTALL GENERATOR COIL ASSEMBLY

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	21 mm Deep Socket Wrench

Install 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 hole.

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 PULLEY WITH CLUTCH

Secure the generator drive end frame in a vise between aluminum plates.
Temporarily install the generator pulley with clutch to the rotor shaft.

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

SST: 09820-63021

NOTE:

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

*a	Generator 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)

NOTE:

Be careful as the generator pulley with clutch or generator 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 [10/2017 - 09/2020] , or refer to PRECAUTION [09/2020 - ]
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)

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

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

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