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Section 121 (Charging): Generator: Reassembly

WARNING: This page is about a different car, the 2002 Lexus GS 430. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install rotor to drive end frame.
    1. Place the rectifier end frame on the pulley.
    2. Install the rotor to the rectifier end frame.
      3. Fig 1: Placing Rectifier End Frame On Pulley
      G01132910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Install rectifier end frame.
    1. Place the generator washer on the rotor.
    2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
      Fig 2: Pressing In Rectifier End Frame
      G01132911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cord clip and 3 nuts, and temporarily tighten the 3 nuts.
      Fig 3: Locating Cord Clip
      G01132912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Install pulley.
    1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
    2. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
      1. SST 09820-63011
      2. Torque  : 39 N.m (400 kgf.cm, 29 ft.lbf)
    3. Check that SST (A) is secured to the pulley shaft.
      Fig 4: Tightening Pulley Nut By Hand
      G01132913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mount SST (C) in a vise.
    5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
      Fig 5: Mounting SST In Vise
      G01132914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
      1. Torque  : 110.5 N.m (1125 kgf.cm, 82 ft.lbf)
    7. Remove the generator from SST (C).
    8. Turn SST (B), and remove SST (A and B).
      Fig 6: Turning SST In Proper Direction
      G01132915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Install rectifier holder.
    1. Install the 4 rubber insulators on the lead wires.
      NOTE: Be careful of the rubber insulators installation direction.
      Fig 7: Installing Rectifier Holder
      G01132916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rectifier holder while pushing it with the 4 screws.
      1. Torque  : 2.94 N.m (30 kgf.cm, 26 in.lbf)
        Fig 8: Pushing Rectifier Holder In With Screws
        G01132917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the cord clip and nut.
      Fig 9: Installing Cord Clip & Nut
      G01132918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 4 nuts.
      1. Torque  :
        • 4.5 N.m (46 kgf.cm, 40 in.lbf) for A
        • 5.4 N.m (55 kgf.cm, 48 in.lbf) for B
  5. Install voltage regulator and brush holder.
    1. Place the seal plate on the rectifier end frame.
      Fig 10: Placing Seal Plate To Rectifier End Frame
      G01132919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the voltage regulator and brush holder on the rectifier end frame.
      NOTE: Be careful of the holder installation direction.
    3. Install the 5 screws.
      1. Torque  : 2.0 N.m (20 kgf.cm, 18 in.lbf)
      Fig 11: Placing Voltage Regulator
      G01132920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Install rear end cover.
    1. Place the brush holder cover on the brush holder.
      Fig 12: Installing Brush Holder Cover
      G01132921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the end cover and plate terminal with the bolt and 3 nuts.
      1. Torque  :
        • 4.4 N.m (45 kgf.cm, 39 in.lbf) for nut
        • 3.8 N.m (39 kgf.cm, 34 in.lbf) for bolt
    3. Install the terminal insulator with the nut.
      1. Torque  : 6.5 N.m (66 kgf.cm, 58 in.lbf)
  7. Check that rotor rotates smoothly.
    Fig 13: Installing End Cover & Plate Terminal
    G01132922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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