Reassembly

1AR-FE BATTERY / CHARGING: GENERATOR: REASSEMBLY

1. INSTALL GENERATOR ROTOR ASSEMBLY

(a) Place the generator drive end frame on the generator pulley with clutch.





(b) Install the generator rotor assembly to the generator drive end frame.

(c) Place a new generator washer on the generator rotor assembly.





2. INSTALL GENERATOR COIL ASSEMBLY

(a) Using a deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly.





Text in Illustration





(b) Install the 4 bolts.

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





3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

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





Text in Illustration





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





Text in Illustration





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

(c) Pull out the pin from the generator brush holder assembly.

4. INSTALL GENERATOR TERMINAL INSULATOR

(a) Install the terminal insulator onto the generator coil assembly.





NOTICE:
Pay attention to installation direction of the terminal insulator.

5. 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)

6. INSTALL GENERATOR PULLEY WITH CLUTCH

(a) Temporarily install the generator pulley with clutch onto the rotor shaft.

(b) Mount the generator assembly in a vise tightly.

(c) Confirm SST1 and 2 as show in the illustration.





SST : 09820-63021

(d) Place the rotor shaft end into SST1.





Text in Illustration





(e) Fit SST2 to the generator pulley with clutch.





Text in Illustration





(f) Using a wrench to hold SST1, turn SST2 clockwise to tighten the generator pulley.





Text in Illustration





without SST - Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)

with SST - Torque : 61 Nm (621 kgf-cm, 45 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).
* This torque value is effective when SST is parallel to a torque wrench.
* Check that the drive end frame is secured in the vise tightly.
* Hold SST1 tightly during the operation.

(g) Remove the generator assembly from SST.

(h) Check that the clutch pulley rotates smoothly.

7. INSTALL GENERATOR PULLEY CAP

(a) Install a new generator pulley cap to the pulley.