Disassembly and Reassembly
Generator (5VZ-FE) Exploded View:
GENERATOR DISASSEMBLY
1. REMOVE REAR END COVER
a. Remove the nut and terminal insulator.
b. Remove the 3 nuts and end cover.
2. REMOVE BRUSH HOLDER
a. Remove the 2 screws, brush holder and cover.
b. Remove the brush holder cover from the brush holder.
3. REMOVE VOLTAGE REGULATOR
Remove the 3 screws and voltage regulator.
4. REMOVE RECTIFIER HOLDER
a. Remove the 4 screws and rectifier holder.
b. Remove the 4 rubber insulators.
5. REMOVE PULLEY
a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63010
Torque: 39 N.m (400 kg.cm, 29 ft.lb)
b. Check that SST (A) is secured to the rotor shaft.
c. As shown in the illustration, mount SST (C) in a vise, and install the generator with SST (A) and (B) to SST (C).
d. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.
NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
e. Remove the generator with SST (A) and (B) from SST (C).
f. Turn SST (B) and remove SST (A) and (B).
g. Remove the pulley nut and pulley.
6. REMOVE RECTIFIER END FRAME
a. Remove the 4 nuts.
b. Using SST, remove the rectifier end frame.
SST 09286-46011
c. Using snap ring pliers, remove the generator washer from the rectifier end frame.
7. REMOVE ROTOR FROM DRIVE END FRAME
GENERATOR ASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
Place the generator washer on the rotor.
3. INSTALL RECTIFIER END FRAME
a. Install the generator washer to the rectifier end frame.
NOTE: He careful of the generator washer installation direction.
b. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
c. Install the 4 nuts.
Torque: 4.5 N.m (45 kg.cm, 39 in.lb)
4. INSTALL PULLEY
a. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
b. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63010
Torque: 39 N.m (400 kg.cm, 29 ft.lb)
c. Check that SST (A) is secured to the pulley shaft.
d. As shown in the illustration, mount SST (C) in a vise, and install the generator with SST (A) and (B) to SST (C).
e. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
Torque: 110 N.m (1.125 kg.cm, 81 ft.lb)
f. Remove the generator with SST (A) and (B) from SST (C).
g. Turn SST (B) and remove SST (A) and (B).
5. INSTALL RECTIFIER HOLDER
a. Install the 4 rubber insulators on the lead wires.
b. Install the rectifier with the 4 screws.
Torque: 2.0 N.m (20 kg.cm, 18 in.lb)
6. INSTALL BRUSH HOLDER AND VOLTAGE REGULATOR
a. Place the brush holder cover to the brush holder.
b. Install the voltage regulator and brush holder to the rear end frame horizontally as shown in the illustration.
HINT: Check that the brush holder's cover doesn't slip to one side during installation.
c. Tighten the 5 screws until there is a clearance of at least 1 mm (0.04 in.) between the brush holder cover and connector.
7. GENERATOR INSTALL REAR END COVER
a. Install the end cover with the 3 nuts.
Torque: 4.5 N.m (45 kg.cm, 39 in.lb)
b. Install the terminal insulator with the nut.
Torque: 4.1 N.m (42 kg.cm, 36 in.lb)
8. MAKE SURE ROTOR ROTATES SMOOTHLY