Section 81 (Charging): Generator: Reassembly

WARNING: This page is about a different car, the 2007 Lexus GX 470. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
Fig 1: Identifying Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Place the generator washer on the rotor.
  
  Fig 2: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, slowly press in the coil assembly.
  SST 09285-76010
  
  Fig 3: Pressing In Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the coil assembly with the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 4: Locating Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR 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 09820-63011
  
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
3. Check that SST (A) is secured to the pulley shaft.
  
  Fig 5: Tightening SST (B) Clockwise To Specified Torque
  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 6: Inserting SST (B) Into SST (C)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
  Torque: 111 N*m (1,125 kgf*cm, 81 ft.*lbf)
7. Remove the generator from SST (C).
  
  Fig 7: Tightening Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn SST (B), and remove SST (A and B).
Fig 8: Removing SST (A And B)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. Place the front seal plate on the coil assembly.
  
  Fig 9: Identifying Front Seal Plate On Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the brush holder on the coil assembly with the pin facing upward.
  NOTE: Be careful of the holder installation direction.
3. Install the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
  
  Fig 10: Identifying Brush Holder On Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the pins of the brush holder with the holes of the rear seal plate, and install the rear seal plate.
Fig 11: Aligning Pins Of Brush Holder With Holes Of Rear Seal Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the terminal insulator.
  NOTE: Be careful of the terminal insulator installation direction.
  
  Fig 12: Identifying Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the end cover with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*ibf)