Charging System (1AR-FE): Generator: Reassembly

INSTALL GENERATOR ROTOR ASSEMBLY
1. Place the generator drive end frame on the generator pulley.
2. Install the generator rotor to the generator drive end frame.
  
  Fig 1: Placing Generator Drive End Frame On Generator Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place the washer on the generator rotor.
Fig 2: Placing Washer On Generator Rotor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSEMBLY
1. Using a 21 mm socket wrench and a press, slowly press in the generator coil.
  
  Fig 3: Pressing In Generator Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 4 bolts.
  Torque: 5.9 N*m (60 kgf*cm, 52 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 into the generator brush holder, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder.
  
  Fig 5: Inserting Pin Into Generator Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator brush holder with the 2 screws.
  Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf)
3. Pull the pin out of the generator brush holder.
Fig 6: Locating Generator Brush Holder Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the terminal insulator onto the generator coil assembly.
  
  Fig 7: Locating Generator Coil Assembly Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the generator rear end cover with the 3 nuts.
  Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf)
INSTALL GENERATOR PULLEY WITH CLUTCH
1. Temporarily install the generator pulley by hand.
2. Mount the generator in a vise.
  
  Fig 8: Locating Generator Rear End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install SST (A) and (B) to the generator pulley as shown in the illustration.
  SST 09820-63021
  
  Fig 9: Installing SST (A) And (B) To Generator Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a wrench to hold SST (A), turn SST (B) clockwise to tighten the generator pulley.
  Torque: without SST
  
  80 N*m (816 kgf*cm, 59 ft.*lbf)
  
  with SST
  
  58 N*m (591 kgf*cm, 43 ft.*lbf)
  NOTE:
  - Use a torque wrench with a fulcrum length of 260 mm (10.24 in.).
  - This torque value is effective when SST is parallel to a torque wrench.
  - Check that the drive end frame is secured in the vise tightly.
  - Hold SST (A) tightly during the operation.
5. Check that the generator pulley rotates smoothly.
Fig 10: Tightening Generator Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR PULLEY CAP
1. Install a new generator pulley cap to the pulley.
Fig 11: Installing Generator Pulley Cap To Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002