Reassembly

1GR-FE CHARGING: GENERATOR: REASSEMBLY

REASSEMBLY

1. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Place the drive end frame on the rotor.
(b) Install the rotor and washer.

2. INSTALL GENERATOR COIL ASSEMBLY

(a) Using SST and a press, press in the coil carefully.
SST: 09285-76010
(b) Install the 4 bolts.
Torque: 5.8 Nm (59 kgf-cm, 51 in-lbf)

3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

(a) Install the plate seal (Inside).
(b) Place the brush holder with the pin facing upward.

NOTICE: Be careful of the brush holder installing direction.

(c) Install the 2 screws.
Torque: 1.8 Nm (18 kgf-cm, 16 in-lbf)
(d) Align the pins of the brush holder with the holes of the plate seal (outside), and install the plate seal (outside).

4. INSTALL TERMINAL INSULATOR
5. INSTALL GENERATOR REAR END COVER
(a) Install the rear end cover with the 3 nuts.
Torque: 4.6 Nm (47 kgf-cm, 41 in-lbf)

6. INSTALL GENERATOR PULLEY

SST: 09820-63011
09820-06010
09820-06021
SST 1-A and B 09820-06010
SST 2 09820-06021

(a) Install the pulley to the rotor shaft by tightening the pulley nut by hand.
(b) Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise with the specified torque.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)

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

(e) Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.
Torque: 111 Nm (1,125 kgf-cm, 81 ft-lbf)
(f) Remove the generator from SST 2.

(g) Turn SST 1-B, and remove SST 1-A, B.
(h) Turn the pulley, and check that the pulley moves smoothly.