2. Install the rotor into the generator cover on the drive side.
3. Install the rectifier block housing.
a) (Models with manual transmission) Install the washer onto the rectifier housing.
b) Using a suitable socket head and press, install the rectifier housing.
c) Install the wiring clamp. Secure the housing with four nuts.
4. Install the pulley.
a) Install the pulley on the rotor shaft nose and hand tighten the pulley mounting nut.
b) Hold the special tool (A) with a torque wrench and tighten the special tool (B).
- Tightening torque - 39 Nm
c) Check that the special tool (A) is securely fixed on the rotor shaft.
d) Clamp the special tool (C) in a vice.
d) Insert the special tool (B) into the special tool (C) and install the pulley nut into the special tool (C).
e) To tighten the pulley mounting nut, turn the special tool (A) clockwise.
- Tightening torque - 110 Nm
g) Remove the generator from the special tool (C).
h) Unscrew the special tool (B) and remove the special tools (A) and (B).
[The original publication can be found on the website: www.ToyotaMan.ru]
5. Install the rectifier unit, a) Install 4 insulators on the wire terminals.
c) Install the rectifier unit and tighten the 4 screws that secure it.
6. Install the voltage regulator and brush holder.
a) Install the brush holder cover onto the brush holder.
b) Install the voltage regulator and brush holder in a horizontal position on the rectifier unit housing, as shown in the figure.
c) Tighten the five brush holder mounting screws so that the gap between the brush holder and the regulator is approximately 1 mm.
d) Adjust the position of the brush holder cover.
7. Install the generator cover on the rectifier block side
a) Install the generator cover and tighten the three nuts and bolt (ZC-T) securing it.
b) Install the terminal by tightening its fastening nut.
c) Install the terminal insulator and secure it with the nut.
8. Check that the rotor rotates smoothly without jamming.