Toyota RAV4 Service Manual: Reassembly

1. Install generator rotor assembly

1. Install the washer onto the generator rectifier end frame.

2. Install the generator rotor onto the generator rectifier end frame.

3. Using a 32 mm socket wrench and press, slowly push the generator drive end frame onto the generator rectifier end frame.

4. Tighten the 4 bolts.

Torque: 5.8 N*m (59 kgf*cm, 51 in.*Lbf)

5. Install the cord clip with the bolt.

Torque: 4.6 N*m (47 kgf*cm, 41 in.*Lbf)

2. Install generator brush holder assembly

1. While pushing the 2 brushes into the generator brush holder, insert a 1.0 Mm (0.039 In.) Pin into the generator brush holder.

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.

4. Install the terminal insulator onto the generator rectifier end frame.

5. 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. Install the pulley by hand.
2. Install sst to the pulley and vise as shown in the illustration.

Sst 09820-63020

3. Turn sst (b) counterclockwise to tighten the pulley.

   Torque: 111 n*m (1125 kgf*cm, 81 ft.*Lbf)

4. Install a new cap to the pulley.
5. Check that the generator pulley rotates smoothly.