Section 24 (Charging System): Generator: Reassembly

WARNING: This page is about a different car, the 2008 Toyota Avalon. 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 generator drive end frame bearing.
  SST 09950-60010 (09951-00470), 09950-70010 (09951-07100)
  
  Fig 1: Installing Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the bearing retainer with the 4 screws.
  Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
INSTALL GENERATOR ROTOR ASSEMBLY
1. Install the generator rotor assembly and generator washer to the drive end frame.
  
  Fig 2: Locating Bearing Retainer And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Using deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly.
  
  Fig 3: Pressing Generator Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 4 bolts.
  Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf)
  
  Fig 4: Locating Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. While pushing the 2 brushes to the inside of the generator brush holder assembly, insert a 1.0 mm (0.039 in.) pin into the generator brush holder hole.
  
  Fig 5: Identifying Pin Into Generator Brush Holder Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the brush holder assembly with the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Remove the pin from the brush holder assembly.
  
  Fig 6: Locating Pin Of Brush Holder Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TERMINAL INSULATOR
1. Install the terminal insulator.
  NOTE: Pay attention to installation direction of the terminal insulator.
  
  Fig 7: Identifying Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the end cover with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
  
  Fig 8: Locating End Cover With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR WITH CLUTCH PULLEY
1. Set SST (A) and (B).
  SST 09820-63020
  1. Set the rotor shaft to SST (A).
  2. Mount SST (A) in a vise.
    
    Fig 9: Identifying SST (A) And (B)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator with the SST as shown in the illustration.
3. Turn SST (B) counterclockwise, and tighten the generator pulley.
  SST 09820-63020
  
  Torque: 87 N*m (891 kgf*cm, 64 ft.*lbf)
  
  NOTE: Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
  
  Fig 10: Tightening Generator Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the generator from the SST.
  NOTE: Check that the generator pulley rotates smoothly.
5. Install a new generator pulley cap.