Reassembly

1GR-FE CHARGING: GENERATOR: REASSEMBLY

1. INSTALL GENERATOR DRIVE END FRAME BEARING

(a) Using SST and a press, press in a new bearing.

SST : 09950-60010

09951-00250

SST : 09950-70010

09951-07100

(b) Install the retainer plate with 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 rotor.

(b) Install the rotor and washer.

3. INSTALL GENERATOR COIL ASSEMBLY

(a) Using a deep socket wrench 21 and a press, in the generator rectifier end frame carefully.

(b) Install the 4 bolts.

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

4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

(a) While pushing the 2 brushes to inside the brush holder, insert a pin (dia1.0 mm (0.039 in.)) into the brush holder hole.

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

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

(c) Pull out the pin (dia1.0 mm (0.039 in.)) from the generator brush hold.

5. INSTALL TERMINAL INSULATOR

(a) Install the terminal insulator to the generator rectifier end frame.

NOTICE:
Pay attention the mounting orientation of the terminal insulator.

6. INSTALL REAR GENERATOR END COVER

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

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

7. INSTALL GENERATOR PULLEY

SST : 09820-63011

09820-06010

09820-06021

HINT

(a) Install the pulley onto the rotor shaft by tightening the pulley nut by hand.

(b) Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque.

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

NOTICE:
Check that SST is secured to the rotor shaft.

(c) Mount SST 2 in a vise.

(d) Insert SST 1-A and B into SST 2, and attach the pulley nut to SST 2.

(e) Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.

Torque : 133 Nm (1351 kgf-cm, 98 ft-lbf)

(f) Remove the generator from SST 2.

(g) Turn SST 1-B, and remove SST 1-A and B.

(h) Turn the pulley and check that the pulley moves smoothly.