Reassembly [06/2018 - ]: Procedure

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INSTALL GENERATOR DRIVE END FRAME BEARING

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

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

Place the generator drive end frame on the generator pulley with clutch.

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 PULLEY WITH CLUTCH

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

Place the rotor shaft end into SST (A).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Rotor Shaft

SST: 09820-63021

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

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

Specified tightening torque

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Hold
*b	Turn
*c	Length of SST 100 mm (3.94 in.)
*d	Length of Torque Wrench 400 mm (1.31 ft.)

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Refer to PRECAUTION [06/2018 - ]
When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (1.312 ft.)): 64 N.m (653 kgf/cm, 47 ft.lbf)

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

INSTALL GENERATOR COIL ASSEMBLY

Install a new bearing cover packing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Protrusion
*b	Groove

NOTE:

Align the protrusions of the bearing cover packing with the grooves of the generator coil assembly when installing.

Using a 21 mm socket wrench and press, slowly press the generator coil assembly to install it.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	21 mm Socket Wrench

Install the 4 bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 5.6 N.m (57 kgf/cm, 50 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.

*a	Pin (1.0 mm)

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

*a	Pin (1.0 mm)
	Pull out

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

Install the generator terminal insulator to the generator coil assembly.

NOTE:

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

INSTALL GENERATOR REAR END COVER

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

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

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