Section 278 (Charging System): Generator: Reassembly

WARNING: This page is about a different car, the 2008 Toyota FJ Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL GENERATOR DRIVE END FRAME BEARING
1. Using SST and a press, press in a new bearing.
  SST 09950-60010 (09951-00470), 09950-70010 (09951-07100)
2. Install the retainer plate with the 4 screws.
  Torque: 2.6 N*m (27 kgf*cm, 23 in.*lbf)
INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the drive end frame on the rotor.
  
  Fig 1: Installing Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rotor and washer.
INSTALL GENERATOR COIL ASSEMBLY
1. Using SST and a press, press in the coil carefully.
  SST 09285-76010
2. Install the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 2: Identifying Generator Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. Install the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
  
  Fig 3: Identifying Generator Brush Holder Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TERMINAL INSULATOR
INSTALL GENERATOR REAR END COVER
1. Install the rear end cover with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)

INSTALL GENERATOR PULLEY

SST 09820-63010(09820-06010,09820-06020)

HINT

SPECIAL TOOL TABLE

SST 1-A and B	09820-06010
SST 2	09820-06020

Install the pulley onto the rotor shaft by tightening the pulley nut by hand.
Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise with the specified torque.
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)

NOTE: Check that SST is secured to the rotor shaft.

Fig 4: Identifying SST 1-A With Torque Wrench
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Mount SST 2 in a vice.
Insert SST 1 -A and B into SST 2, and attach the pulley nut to SST 2.

Fig 5: Attaching Generator Pulley Nut To SST 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Tighten the pulley nut by turning SST 1-A in the direction shown in Fig 6.
Torque: 111 N*m (1,132 kgf*cm, 82 ft.*lbf)

Fig 6: Identifying Pulley Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the generator from SST 2.
Turn SST 1-B, and remove SST 1-A and B.
Turn the pulley, and check that the pulley moves smoothly.

Fig 7: Identifying Generator Pulley Operation
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002