Section 132 (Charging System (2GR-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 Onto Generator Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a 21 mm deep socket wrench and press, slowly push the generator drive end frame onto the generator rectifier frame.
  
  Fig 3: Pushing Generator Drive End Frame Onto Generator Rectifier Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 4: Installing Generator Case Bolts
  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.) diameter pin into the generator brush holder.
  
  Fig 5: Inserting A 1.0 mm (0.039 in.) Diameter Pin Into Generator Brush Holder
  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)
  
  Fig 6: Installing Generator Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pull the pin out of the generator brush holder.
4. Install the terminal insulator onto the generator rectifier end frame.
  
  Fig 7: 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 8: Installing Generator Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the bracket with the bolt.
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
  
  Fig 9: Installing Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the wire harness clamp stay.
  Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
  
  Fig 10: Installing Wire Harness Clamp Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR PULLEY WITH CLUTCH
1. Install the pulley by hand.
2. Install SST to the pulley as shown.
  SST 09820-63020
  
  Fig 11: 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)
  
  Fig 12: Turning SST (B) Counterclockwise To Tighten Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install a new cap to the pulley.
5. Check that the generator pulley rotates smoothly.