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Reassembly [12/2015 - 08/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL GENERATOR ROTOR ASSEMBLY 
    1. Place the drive end frame on the clutch pulley.
    2. Install the generator rotor assembly to the drive end frame.
      GTY703605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place a new generator washer on the generator rotor assembly.
      GTY692319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL GENERATOR CLUTCH PULLEY 
    1. Temporarily install the clutch pulley onto the rotor shaft.
    2. Mount the generator drive end frame in a vise tightly.
    3. Assemble SST1 and 2 as shown in the illustration.
      GTY711839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09820-63021 
    4. Place the rotor shaft end into SST1.
      GTY726712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Rotor Shaft
    5. Fit SST2 to the clutch pulley.
      GTY688012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Clutch Pulley
    6. Tighten the pulley by turning SST2 in the direction shown in the illustration.
      GTY723249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
      *c Fulcrum Length: 100 mm
      *d Fulcrum Length: 318 mm

      without SST 

      Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 

      with SST 

      Torque: 61 N*m (621 kgf*cm, 45 ft.*lbf) 

      NOTE:
      • 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.
      • Check that the drive end frame is secured in the vise tightly.
      • Hold SST1 tightly during the operation.
    7. Remove the generator assembly from SST.
    8. Check that the clutch pulley rotates smoothly.
    9. Install a new generator pulley cap to the clutch pulley.
  3. INSTALL GENERATOR COIL ASSEMBLY 
    1. Using a deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly.
      GTY251098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Deep Socket Wrench (21 mm)
    2. Install the 4 bolts.
      GTY442330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf) 

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY 
    1. While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.039 in.) pin into the brush holder hole.
      GTY734428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pin (1.0 mm)
    2. Install the brush holder assembly with the 2 screws.
      GTY735542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pin (1.0 mm)

      Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) 

    3. Pull out the pin from the generator brush holder.
  5. INSTALL GENERATOR TERMINAL INSULATOR 
    1. Install the terminal insulator.
      GTY722881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Pay attention to installation direction of the terminal insulator.

  6. INSTALL GENERATOR REAR END COVER 
    1. Install the generator rear end cover with the 3 nuts.
      GTY442329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf) 

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