Reassembly

2AZ-FE CHARGING: GENERATOR: REASSEMBLY

REASSEMBLY

1. INSTALL GENERATOR ROTOR ASSEMBLY






(a) Install the washer onto the generator rectifier end frame.






(b) Install the generator rotor onto the generator rectifier end frame.






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






(d) Tighten the 4 bolts.
Torque: 5.8 Nm (59 kgf-cm, 51 in-lbf)






(e) Install the cord clip with the bolt.
Torque: 4.6 Nm (47 kgf-cm, 41 in-lbf)
2. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY






(a) While pushing the 2 brushes into the generator brush holder, insert a 1.0 mm (0.039 in.) pin into the generator brush holder.






(b) Install the generator brush holder with the 2 screws.
Torque: 1.8 Nm (18 kgf-cm, 16 in-lbf)
(c) Pull the pin out of the generator brush holder.






(d) Install the terminal insulator onto the generator rectifier end frame.






(e) Install the generator rear end cover with the 3 nuts.
Torque: 4.6 Nm (47 kgf-cm, 41 in-lbf)
3. INSTALL GENERATOR PULLEY WITH CLUTCH
(a) Install the pulley by hand.






(b) Install SST to the pulley and vise as shown in the illustration.
SST: 09820-63020






(c) Turn SST (B) counterclockwise to tighten the pulley.
Torque: 110 Nm (1122 kgf-cm, 82 ft-lbf)
(d) Install a new cap to the pulley.
(e) Check that the generator pulley rotates smoothly.