Section 118 (Charging System (2AZ-FE)): Generator: Reassembly

WARNING: This page is about a different car, the 2007 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL GENERATOR ROTOR ASSEMBLY
1. Install the washer onto the generator rectifier end frame.
  
  Fig 1: Installing Washer Onto Generator Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator rotor onto the generator rectifier end frame.
  
  Fig 2: Installing Generator Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a 32 mm socket wrench and press, slowly push the generator drive end frame onto the generator rectifier end frame.
  
  Fig 3: Pushing Generator Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Tighten the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 4: Tightening End Frame Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the cord clip with the bolt.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
  
  Fig 5: Installing Cord Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. While pushing the 2 brushes into the generator brush holder, insert a 1.0 mm (0.039 in.) pin into the generator brush holder.
  
  Fig 6: Installing Generator Brush Holder Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator brush holder with the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Pull the pin out of the generator brush holder.
  
  Fig 7: Pulling Pin Out Of Generator Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the terminal insulator onto the generator rectifier end frame.
  
  Fig 8: Installing Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the generator rear end cover with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
  
  Fig 9: Installing Generator Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR PULLEY WITH CLUTCH
1. Install the pulley by hand.
2. Install SST to the pulley and vise as shown..
  SST 09820-63020
  
  Fig 10: Installing SST To Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn SST (B) counterclockwise to tighten the pulley.
  Torque: 111 N*m (1125 kgf*cm, 81 ft.*lbf)
4. Install a new cap to the pulley.
  
  Fig 11: Installing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Check that the generator pulley rotates smoothly.