Reassembly [11/2021 - ]: Procedure

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using SST and a press, install a new generator drive end frame bearing.
      • SST: 09950-60011 
        1. 09951-00470
      • SST: 09950-70010 
        1. 09951-07100

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Tab

   *b

   Cutout

   1. Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.
   2. Install the 4 screws.

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Place a new washer on the generator rotor assembly.
      NOTE:

      Make sure to install the washer so that its cutout faces the bearing side, as the washer must be installed in a specific direction.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Using SST and press, slowly press in the generator coil assembly.
      • SST: 09612-70100 
        1. 09612-07240
   2. Install the 4 bolts.

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Pin (1.0 mm)	-	-
   	Pull out	-	-

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

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

   3. Pull out the pin from the generator brush holder assembly hole.

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Generator Pulley with Clutch	-	-
   *a	Rotor Shaft	-	-

   1. Secure the generator drive end frame in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

   2. Temporarily install a new generator pulley with clutch to the rotor shaft.
   3. Install SST (A) to SST (B) as shown in the illustration.
      • SST: 09820-63021 
   4. Fit the rotor shaft end into SST (A).
   5. Fit SST (B) to the generator pulley with clutch.

      HINT: 

      Make sure that SST (A) and (B) are secured to the rotor shaft and generator pulley with clutch.

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   1. 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.
      • Check that the generator pulley with clutch rotates smoothly.

      HINT: 

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

        Refer to PRECAUTION [11/2021 - ]

      • 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)
   2. Remove SST (A) and (B) from the generator pulley with clutch.
   3. Remove the generator drive end frame from the vise.