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Generator ASSY (1ZZ-FE/2ZZ-GE): Replacement

  1. DISCONNECT BATTERY NEGATIVE TERMINAL 
  2. REMOVE CYLINDER HEAD COVER NO.2 (2ZZ-GE ENGINE TYPE) (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REAS  ) 
  3. REMOVE AIR SWITCHING VALVE ASSY (2ZZ-GE ENGINE TYPE) (See  REPLACEMENT  ) 
  4. REMOVE ENGINE UNDER COVER RH 
  5. REMOVE FAN AND GENERATOR V BELT 

    HINT:

  6. REMOVE AIR PUMP OUTLET PIPE (2ZZ-GE ENGINE TYPE) 
    1. Disconnect the air hose No. 5.
    2. Remove the 2 bolts, then remove the air pump outlet pipe.
    Fig 1: Removing Air Pump Outlet Pipe
    G02613852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE GENERATOR ASSY 
    1. Remove the wire harness clamp. (2ZZ-GE ENGINE TYPE)
    2. Remove the terminal cap No. 2.
    3. Remove the nut, then remove the generator wire.
    4. Disconnect the generator connector.
    5. Remove the wire harness clamp.
    6. Disconnect the A/C connector.
      Fig 2: Disconnecting A/C Connector
      G02613853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the bolt, then remove the wire harness clamp bracket. (2ZZ-GE ENGINE TYPE)
      Fig 3: Removing Wire Harness Clamp Bracket
      G02613854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 2 bolts, then remove the generator bracket No. 1. (2ZZ-GE ENGINE TYPE)
      Fig 4: Removing Generator Bracket
      G02613855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 2 bolts, then remove the generator.
    Fig 5: Removing Generator
    G02613856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL GENERATOR ASSY 
    1. Install the generator with the 2 bolts.

      Torque: 

      25 N.m (250 kgf.cm, 18 ft.lbf) for bolt A 

      54 N.m (550 kgf.cm, 40 ft.lbf) for bolt B (1ZZ-FE ENGINE TYPE) 

      58 N.m (590 kgf.cm, 43 ft.lbf) for bolt B (2ZZ-GE ENGINE TYPE) 

      Fig 6: Installing Generator
      G02613857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the wire harness clamp bracket with the bolt. (2ZZ-GE ENGINE TYPE)

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

      Fig 7: Installing Wire Harness Clamp Bracket
      G02613858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the A/C connector.
    4. Install the wire harness clamp.
    5. Connect the generator connector.
    6. Install the generator wire with the nut.

      Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf) 

    7. Install the terminal cap No. 2.
      Fig 8: Installing Terminal Cap No. 2
      G02613859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the generator bracket No. 1 with the 2 bolts. (2ZZ-GE ENGINE TYPE)

      Torque: 29 N.m (296 kgf.cm, 21.ft.lbf) 

    9. Install the wire harness clamp.
    Fig 9: Installing Generator Bracket & Wire Harness Clamp
    G02613860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL AIR PUMP OUTLET PIPE (2ZZ-GE ENGINE TYPE)
    1. Install the air pump outlet pipe with the 2 bolts.

      Torque: 7.0 N.m (71 kgf.cm, 62 in. bf) 

    2. Connect the air hose No. 5.
    Fig 10: Connecting Air Hose
    G02613861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FAN AND GENERATOR V BELT 

    HINT:

  11. INSTALL ENGINE UNDER COVER RH 
  12. INSTALL AIR SWITCHING VALVE ASSY (2ZZ-GE ENGINE TYPE) (See  AIR SWITCHING VALVE ASSY (2ZZ-GE)  ) 
  13. INSTALL CYLINDER HEAD COVER NO.2 (2ZZ-GE ENGINE TYPE) (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REAS  ) 
  14. CONNECT BATTERY NEGATIVE TERMINAL 

    Torque: 54 N.m (55 kgf.cm, 48 in. bf) 

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