Charging (2GR-FSE): Generator: Reassembly

INSTALL GENERATOR DRIVE END FRAME BEARING
1. Using SST and a press, press in a new generator drive end frame bearing.
  SST 09950-60010 (09951-00470), 09950-70010 (09951-07100)
  
  Fig 1: Pressing Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.
3. Install the 4 screws.
  Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the drive end frame on the clutch pulley.
  
  Fig 2: Installing Retainer Plate With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rotor assembly to the drive end frame.
  
  Fig 3: Installing Rotor Assembly To Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place a new generator washer on the generator rotor.
  
  Fig 4: Placing Generator Washer On Generator Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Using SST and a press, press in the generator coil assembly to the drive end frame.
  SST 09612-70100 (09612-07240)
  
  Fig 5: Pressing Generator Coil Assembly To Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator coil assembly with the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 6: Installing Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 7: Inserting Pin Into Brush Holder Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator brush holder assembly to the generator coil with the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Pull out the pin from the generator brush holder.
  
  Fig 8: Installing Generator Brush Holder Assembly To Generator Coil With Torque Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TERMINAL INSULATOR
1. Install the terminal insulator to the generator coil.
  
  Fig 9: Installing Terminal Insulator To Generator Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the generator rear end cover to the generator coil with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
INSTALL CLUTCH PULLEY
1. Temporarily install the clutch pulley onto the rotor shaft.
  
  Fig 10: Installing Clutch Pulley Onto Rotor Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set SST (A) and (B).
  SST 09820-63020
  
  Fig 11: Setting SST (A) And (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Clamp SST (A) in a vise.
4. Place the rotor shaft end into SST (A).
  
  Fig 12: Placing Rotor Shaft End Into SST (A)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 13: Fitting SST To Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten the pulley by turning SST (B) in the direction shown in the illustration.
  Torque: 111 N*m (1,127 kgf*cm, 81 ft.*lbf)
  
  NOTE: The torque shown above should be used for tightening without using SST. When the SST is used for tightening, the torque should be calculated based on the length of the SST (See PRECAUTION ).
7. Remove the generator assembly from the SST.
8. Check that the clutch pulley rotates smoothly.
9. Install the new clutch pulley cap to the clutch pulley.
  
  Fig 14: Tightening Pulley With Torque Specifications
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002