Reassembly
2AR-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
09951-00520
SST : 09950-70010
09951-07100
(b) Fit the tabs on the bearing retainer into the cutouts on the drive end frame to install the bearing retainer.
Text in Illustration
(c) Install the 4 screws.
Torque : 2.3 Nm (23 kgf-cm, 20 in-lbf)
2. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Place the generator drive end frame on the generator pulley.
(b) Install the generator rotor to the generator drive end frame.
(c) Place a new generator washer on the generator rotor.
3. INSTALL GENERATOR COIL ASSEMBLY
(a) Using a 21 mm socket wrench and a press, slowly press in the generator coil.
Text in Illustration
(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 1.0 mm (0.0394 in.) pin into the generator brush holder.
Text in Illustration
(b) Install the generator brush holder with the 2 screws.
Text in Illustration
Torque : 1.8 Nm (18 kgf-cm, 16 in-lbf)
(c) Pull the pin out of the generator brush holder.
5. INSTALL GENERATOR REAR END COVER
(a) Install the terminal insulator onto the generator coil assembly.
(b) Install the generator rear end cover with the 3 nuts.
Torque : 4.6 Nm (47 kgf-cm, 41 in-lbf)
6. INSTALL GENERATOR PULLEY WITH CLUTCH
(a) Temporarily install the generator pulley by hand.
(b) Mount the generator in a vise.
(c) Install SST (A) and (B) to the generator pulley as shown in the illustration.
Text in Illustration
SST : 09820-63021
(d) Using a wrench to hold SST (A), turn SST (B) clockwise to tighten the generator pulley.
Text in Illustration
without SST - Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)
with SST - Torque : 57 Nm (581 kgf-cm, 42 ft-lbf)
NOTICE:
* The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.) and a torque wrench with a fulcrum length of 255 mm (10.04 in.) Service Precautions.
* The "with SST" torque value is effective when SST is parallel to the torque wrench
* Check that the drive end frame is secured in the vise tightly.
* Hold SST (A) tightly during the operation.
(e) Check that the generator pulley rotates smoothly.
7. INSTALL GENERATOR PULLEY CAP
(a) Install a new generator pulley cap to the pulley.
