Section 32 (Charging System (2ZR-FE) (Service Information)): Generator: Reassembly: Reassembly

WARNING: This page is about a different variant/trim than selected.

INSTALL GENERATOR DRIVE END FRAME BEARING
1. Using SST and a press, press in a new generator drive end frame bearing.
  
  Fig 1: Pressing Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00470
  - SST: 09950-70010
    - 09951-07100
2. Fit the tabs of the bearing retainer plate into the cutouts on the generator drive end frame to install the bearing retainer plate.
  
  Fig 2: Identifying Retainer Plate Into Cutouts On Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 4 screws.
  Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the drive end frame on the clutch pulley.
2. Install the generator rotor assembly to the generator drive end frame.
  
  Fig 3: Locating Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place the generator washer on the generator rotor.
  
  Fig 4: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Using SST and a press, slowly press in the generator coil assembly to the drive end frame.
  
  Fig 5: Pressing Generator Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09612-70100
    - 09612-07240
2. Install the 4 bolts.
  
  Fig 6: Locating Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
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 hole.
  
  Fig 7: Inserting Pin Into Brush Holder Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the brush holder assembly to the generator coil with the 2 screws.
  
  Fig 8: Locating Generator Coil With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Pull out the pin from the generator brush holder assembly.
  
  Fig 9: Pulling Pin From Generator Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR TERMINAL INSULATOR
1. Install the terminal insulator to the generator coil.
  
  Fig 10: Locating Generator Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful to follow the installation direction of the terminal insulator as shown in the illustration.
INSTALL GENERATOR REAR END COVER
1. Install the generator rear end cover to the generator coil with the 3 nuts.
  
  Fig 11: Locating Generator Rear End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
INSTALL GENERATOR CLUTCH PULLEY
1. Temporarily install the clutch pulley onto the rotor shaft.
2. Set SST (A) and (B).
  
  Fig 12: Setting SST (A) And (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09820-63021
3. Clamp SST (A) in a vise.
  
  Fig 13: Identifying Rotor Shaft End And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the rotor shaft end into SST (A).
5. Fit SST (B) to the clutch pulley.
  
  Fig 14: Fitting SST To Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten the pulley by turning SST (B) in the direction shown in the illustration.
  
  Fig 15: Tightening Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  without SST
  
  Torque: 111 N*m (1127 kgf*cm, 82 ft.*lbf)
  
  with SST
  
  Torque: 84 N*m (857 kgf*cm, 62 ft.*lbf)
  NOTE:
  - The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.).
  - Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).
  - This torque value is effective when SST is parallel to the torque wrench.
7. Remove the generator assembly from SST.
8. Check that the clutch pulley rotates smoothly.
9. Install a new clutch pulley cap to the clutch pulley.