Section 276 (Charging System - Generators & Regulators - 2UZ-FE): Generator: Reassembly

WARNING: This page is about a different car, the 2002 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.

Place Rectifier End Frame On Pulley
Install Rotor To Drive End Frame

Fig 1: Installing End Rotor To Drive End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Rectifier End Frame
1. Place the generator washer on the rotor.
  
  Fig 2: Placing Generator Washer On Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
  
  Fig 3: Using Specified Socket Wrench Press In Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 3 nuts.
  1. Torque:
  2. 4.5 N.m (46 kgf.cm, 39 in.lbf)
Fig 4: Locating Nuts In Rectifier Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Pulley
1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
2. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
  SST 09820-63011
  1. Torque:
  2. 39 N.m (400 kgf.cm, 29 ft.lbf)
  Fig 5: Tightening Nut By Hand
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check that SST (A) is secured to the pulley shaft.
4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
  
  Fig 6: Locating SST (B) & SST (C) For Attachment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown.
  1. Torque:
  2. 110.5 N.m (1,125 kgf.cm, 81 ft.lbf)
7. Remove the generator from SST (C).
8. Turn SST (B), and remove SST (A and B).
Fig 7: Removing Generator From SST (C)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Rectifier Holder
1. Install the 4 rubber insulators on the lead wires.
  NOTE: Be careful of the rubber insulators installation direction.
  
  Fig 8: Installing Insulators On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier with the 4 screws.
  1. Torque:
  2. 2.94 N.m (30 kgf.cm, 26 in.lbf)
  Fig 9: Installing Rectifier With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cord clip with the nut.
  1. Torque:
  2. 5.4 N.m (55kgf.cm, 48 in.lbf)
Fig 10: Installing Cord Clip & Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Brush Holder And Voltage Regulator
1. Place the seal plate on the rectifier end frame.
  
  Fig 11: Placing Seal Plate On Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the voltage regulator and brush holder on the rectifier end frame.
  NOTE: Be careful of the brush holder installation direction.
3. Install the 5 screws.
  1. Torque:
  2. 1.96 N.m (20 kgf.cm, 17 in.lbf)
  Fig 12: Placing Voltage Regulator & Brush Holder On Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the brush holder cover on the brush holder.
Fig 13: Placing Brush Holder Cover On Brush Holder
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install Rear End Cover
1. Install the end cover and plate terminal with the bolt and 3 nuts.
  1. Torque:
  2. Bolt: 3.85 N.m (39 kgf.cm, 34 in.lbf)
  3. Nut: 4.4 N.m (46 kgf.cm, 39 in.lbf)
  Fig 14: Installing End Cover & Plate Terminal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the terminal insulator with the nut.
  1. Torque:
  2. 4.1 N.m (41.5 kgf.cm, 36 in.lbf)
Fig 15: Installing Rear End Insulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check That Rotor Rotates Smoothly