Reassembly

2GR-FSE CHARGING: GENERATOR: REASSEMBLY

1. INSTALL GENERATOR DRIVE END FRAME BEARING

(a) Using SST and a press, press in a new generator drive end frame bearing.

SST : 09950-60010

09951-00470

SST : 09950-70010

09951-07100

(b) Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.

(c) Install 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 clutch pulley.

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

3. INSTALL GENERATOR COIL ASSEMBLY

(a) Using SST and a press, press in the generator coil to the drive end frame.

SST : 09612-70100

09612-07240

(b) Install the generator coil with 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 into the generator brush holder assembly, insert a dia1.0 mm (0.039 in.) pin into the brush holder hole.

(b) Install the generator brush holder 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 TERMINAL INSULATOR

(a) Install the terminal insulator to the generator coil.

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)

7. INSTALL CLUTCH PULLEY

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

(b) Set SST (A) and (B).

SST : 09820-63020

(c) Clamp SST (A) in a vise.

(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.

Torque : 111 Nm (1127 kgf-cm, 81 ft-lbf)

(g) Remove the generator assembly from SST.

(h) Check that the clutch pulley rotates smoothly.

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