Reassembly
1GR-FE 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) Install the generator rotor assembly to the drive end frame.
(b) Place the generator washer on the generator rotor.
3. INSTALL GENERATOR COIL ASSEMBLY
(a) Using a deep socket wrench (21 mm) and 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)
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
(a) While pushing the 2 brushes into the generator brush holder, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the brush holder hole.
Text in Illustration
(b) Install the generator brush holder to the generator coil 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.
5. INSTALL GENERATOR TERMINAL INSULATOR
(a) Install the terminal insulator to the generator coil.
NOTICE:
Pay attention to installation direction of the terminal insulator.
6. INSTALL GENERATOR REAR END COVER
(a) Install the generator rear end cover to the generator coil with the 3 nuts.
Torque : 4.6 Nm (46 kgf-cm, 40 in-lbf)
(b) Install the cord clamp with the nut.
Torque : 6.2 Nm (63 kgf-cm, 55 in-lbf)
7. INSTALL GENERATOR CLUTCH PULLEY
(a) Temporarily install the generator with clutch pulley by hand.
(b) Mount the generator in a vise between aluminum plates.
(c) Install SST (A) and (B) to the generator with clutch pulley as shown in the illustration.
Text in Illustration
SST : 09820-63021
NOTICE:
Securely attach SST to the generator with clutch pulley and generator rotor shaft.
(d) Using a wrench to hold SST (A), turn SST (B) clockwise to tighten the generator with clutch pulley.
Text in Illustration
without SST - Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)
with SST - Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)
NOTICE:
* Be careful as the generator with clutch pulley or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.
* Use a torque wrench with a fulcrum length of 400 mm (15.7 in.).
* The torque value for use with SST is effective when SST is parallel to the torque wrench.
(e) Remove SST from the generator.
(f) Check that the generator with clutch pulley rotates smoothly.
8. INSTALL GENERATOR PULLEY CAP
(a) Install a new clutch pulley cap to the clutch pulley.