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: 2.2 Nm (22 kgf-cm, 19 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.

NOTE: 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

(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)

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

(e) Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.
Torque: 111 Nm (1,125 kgf-cm, 81 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.