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Reassembly [09/2020 - ]: Procedure

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  1. INSTALL GENERATOR DRIVE END FRAME BEARING 
    1. Using SST and a press, install a new generator drive end frame bearing.
      GTY955331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00470
      • SST: 09950-70010 
        1. 09951-07100
    2. Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.
      GTY955345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tab
      *b Cutout
    3. Install the 4 screws.

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

  2. 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.
      GTY946960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Rotor Assembly
      *2 Generator Drive End Frame
  3. INSTALL GENERATOR COIL ASSEMBLY 
    1. Place a new washer on the generator rotor assembly.
      GTY443065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 21 mm deep socket wrench and a press, slowly press in the generator coil assembly.
      GTY955336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 21 mm Deep Socket Wrench
    3. Install the 4 bolts.
      GTY947047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) 

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY 
    1. 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.
      GTY434278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin (1.0 mm)
    2. Install the generator brush holder assembly to the generator coil assembly with the 2 screws.
      GTY483539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin (1.0 mm)
      Pull out

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

    3. Pull out the pin from the generator brush holder assembly hole.
  5. INSTALL GENERATOR TERMINAL INSULATOR 
    1. Install the generator terminal insulator to the generator coil assembly.
      GTY506960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

  6. 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) 

      GTY506959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL GENERATOR PULLEY WITH CLUTCH 
    1. Secure the generator drive end frame in a vise between aluminum plates.
    2. Temporarily install the generator pulley with clutch to the rotor shaft.
    3. Fit the rotor shaft end into SST (A).
      GTY946708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rotor Shaft
      • SST: 09820-63021 
    4. Fit SST (B) to the generator pulley with clutch.
      GTY955340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Pulley with Clutch
    5. 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) 

      NOTE:
      • Check that the generator drive end frame is secured in the vise tightly.
      • Hold SST (A) tightly during the operation.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [09/2020 - ]

      • 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)
      GTY946713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
      *b Turn
      *c Hold
    6. Remove SST (A) and (B) from the generator pulley with clutch.
    7. Check that the generator pulley with clutch rotates smoothly.
    8. Remove the generator drive end frame from the vise.
  8. INSTALL GENERATOR PULLEY CAP 
    1. Install a new generator pulley cap to the generator pulley with clutch.
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