Reassembly

1UR-FE BATTERY / CHARGING: GENERATOR: REASSEMBLY

1. INSTALL GENERATOR DRIVE END FRAME BEARING

(a) Using SST and a press, press in a new bearing.

SST : 09950-60010

09951-00500

SST : 09950-70010

09951-07100

(b) Install the retainer plate with the 4 screws.

Torque : 2.3 Nm (23 kgf-cm, 20 in-lbf)

2. INSTALL GENERATOR ROTOR ASSEMBLY

(a) Install the generator rotor to the drive end frame.

(b) Place the generator washer on the rotor.

3. INSTALL GENERATOR COIL ASSEMBLY

(a) Using a 22 mm socket wrench and press, slowly press in the coil assembly.

(b) Install the 4 bolts.

Torque : 5.9 Nm (60 kgf-cm, 52 in-lbf)

4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

(a) While pushing the 2 brushes into the generator brush holder, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the brush holder hole.

Text in Illustration

(b) Install the generator brush holder with the 2 screws.

Torque : 1.8 Nm (18 kgf-cm, 16 in-lbf)

5. INSTALL TERMINAL INSULATOR

(a) Install the terminal insulator to the generator coil.

NOTICE:
Pay attention to the mounting orientation of the terminal insulator.

6. INSTALL GENERATOR REAR END COVER

(a) Install the generator rear end cover with the 3 nuts.

Torque : 4.6 Nm (46 kgf-cm, 40 in-lbf)

7. INSTALL GENERATOR PULLEY

(a) Temporarily install the generator pulley by hand.

(b) Mount the generator in a vise between aluminum plates.

(c) Install SST 1-A to the pulley shaft.

SST : 09820-63011

09820-06010

09820-06021

HINT

(d) Install SST 1-B to SST 1-A.

(e) Hold SST 1-A with a torque wrench and turn SST 1-B clockwise with the specified torque.

Torque : 39 Nm (398 kgf-cm, 29 ft-lbf)

Text in Illustration

NOTICE:
Check that SST is secured to the rotor shaft.

(f) Insert SST 2 and attach it to the pulley nut.

Text in Illustration

(g) Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.

Torque : 133 Nm (1351 kgf-cm, 98 ft-lbf)

Text in Illustration

HINT
Hold the adjustable wrench against the vise and tighten the nut securely.

(h) Remove the generator from SST 2.

(i) Turn SST 1-B, and then remove SST 1-A and B.

Text in Illustration

(j) Turn the pulley and check that the pulley moves smoothly.