Reassembly

2GR-FE CHARGING: GENERATOR: REASSEMBLY

1. INSTALL GENERATOR ROTOR ASSEMBLY

(a) Place the drive end frame on the clutch pulley.

(b) Install the generator rotor assembly to the drive end frame.

2. INSTALL GENERATOR CLUTCH PULLEY

(a) Temporarily install the clutch pulley onto the rotor shaft.

(b) Mount the generator drive end frame in a vise tightly.

(c) Confirm SST (A) and (B) shown in the illustration.

SST : 09820-63021

(d) Place the rotor shaft end into SST (A).

(e) Fit SST (B) to the clutch pulley.

(f) Tighten the pulley by turning SST (B) in the direction shown in the illustration.

without SST - Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)

with SST - Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

NOTICE:
* The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 400 mm (15.75 in.).
* This torque value is effective when SST is parallel to the torque wrench.
* Hold the generator assembly tightly.

(g) Remove SST from the generator assembly.

(h) Check that the clutch pulley rotates smoothly.

(i) Install a new generator pulley cap to the clutch pulley.

3. INSTALL GENERATOR COIL ASSEMBLY

(a) Place a new generator washer on the generator rotor.

(b) Using a deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly.

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 assembly, insert a dia1.0 mm (0.039 in.) pin into the brush holder hole.

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

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 the 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 (47 kgf-cm, 41 in-lbf)