Reassembly

2GR-FE CHARGING: GENERATOR: REASSEMBLY

1. INSTALL GENERATOR ROTOR ASSEMBLY





(a) Install the washer onto the generator rectifier end frame.





(b) Install the generator rotor onto the generator rectifier end frame.





(c) Using a 21 mm deep socket wrench and press, slowly push the generator drive end frame onto the generator rectifier frame.





(d) Install the 4 bolts.

Torque : 5.8 Nm (59 kgf-cm, 51 in-lbf)

2. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY





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





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

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

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





(d) Install the terminal insulator onto the generator rectifier end frame.





(e) Install the generator rear end cover with the 3 nuts.

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





(f) Install the bracket with the bolt.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)





(g) Install the wire harness clamp stay.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

3. INSTALL GENERATOR PULLEY WITH CLUTCH

(a) Install the pulley by hand.





(b) Install SST to the pulley as shown in the illustration.

SST : 09820-63021





(c) Turn SST (B) counterclockwise to tighten the pulley.

Torque : 110 Nm (1122 kgf-cm, 82 ft-lbf)

(d) Install a new cap to the pulley.

(e) Check that the generator pulley rotates smoothly.