Charging (3UZ-FE): Generator: Reassembly

INSTALL ROTOR TO DRIVE END FRAME
1. Place the rectifier end frame on the pulley.
2. Install the rotor to the rectifier end frame.
INSTALL RECTIFIER END FRAME
1. Place the generator washer on the rotor.
  
  Fig 1: Installing Rotor To Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
  
  Fig 2: Pressing In Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cord clip and 3 nuts, and temporarily tighten the 3 nuts.
  
  Fig 3: Installing Cord Clip And Nuts, And Temporarily Tightening Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  SST 09820-6301 1
  
  Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 4: Installing Pulley To Rotor Shaft
  Courtesy 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: Attaching Pulley Nut To SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  Torque: 110.5 N.m (1,125 kgf.cm, 82 ft.lbf)
7. Remove the generator from SST (C).
8. Turn SST (B), and remove SST (A and B).
Fig 6: Tightening Pulley Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Rubber Insulators On Lead Wires
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rectifier holder while pushing it with the 4 screws.
  Torque: 2.94 N.m (30 kgf.cm, 26 in..lbf)
  
  Fig 8: Installing Rectifier Holder With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cord clip and nut.
4. Tighten the 4 nuts.
  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
  
  Fig 9: Installing Cord Clip And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
1. Place the seal plate on the rectifier end frame.
  
  Fig 10: Placing Seal Plate On Rectifier End Frame
  Courtesy 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.
  Torque: 2.0 N.m (20 kgf.cm, 18 in..lbf)
  
  Fig 11: Installing Screws On Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR END COVER
1. Place the brush holder cover on the brush holder.
  
  Fig 12: Placing Brush Hold Cover On Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the end cover and plate terminal with the bolt and 3 nuts.
  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.
  Torque: 6.5 N.m (66 kgf.cm, 58 in..lbf)
  
  Fig 13: Installing Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK THAT ROTOR ROTATES SMOOTHLY