Reassembly

2GR-FE BATTERY / CHARGING: GENERATOR: REASSEMBLY

1. INSTALL GENERATOR DRIVE END FRAME BEARING

(a) Using SST and a press, press in a new generator drive end frame bearing.

SST : 09950-60010

09951-00470

SST : 09950-70010

09951-07100

(b) Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.

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 drive end frame on the generator pulley with clutch.

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

3. INSTALL GENERATOR PULLEY WITH CLUTCH

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

(b) Mount the generator drive end frame in a vise tightly.

(c) Confirm SST (A) and (B) shown in the illustration.

Text in Illustration

SST : 09820-63021

(d) Place the rotor shaft end into SST (A).

Text in Illustration

(e) Fit SST (B) to the generator pulley with clutch.

Text in Illustration

(f) Tighten the pulley by turning SST (B) in the direction shown in the illustration.

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.

(g) Remove SST from the generator assembly.

(h) Check that the generator pulley with clutch rotates smoothly.

(i) Install a new generator pulley cap to the generator pulley with clutch.

4. INSTALL GENERATOR COIL ASSEMBLY

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

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

Text in Illustration

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

5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

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

Text in Illustration

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

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

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

Text in Illustration

6. INSTALL GENERATOR TERMINAL INSULATOR

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

NOTICE:
Be sure to install the terminal insulator in the correct direction.

7. INSTALL GENERATOR REAR END COVER

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

Torque : 4.6 Nm (47 kgf-cm, 41 in-lbf)