Reassembly

2AZ-FE CHARGING: GENERATOR: REASSEMBLY

REASSEMBLY

1. INSTALL GENERATOR ROTOR ASSEMBLY

(a) Place the generator drive end frame on the generator pulley.
(b) Install the washer onto the generator rectifier end frame.

(d) Using a 32 mm socket wrench and press, slowly push the generator drive end frame onto the generator rectifier end frame.

(e) Tighten the 4 bolts.
Torque: 5.8 Nm (60 kgf-cm, 51 in-lbf)

(f) Install the cord clip with the bolt.
Torque: 4.56 Nm (45 kgf-cm, 40 in-lbf)
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

(a) While pushing the 2 brushes into the generator brush holder, insert a 1.0 mm (0.039 in.) pin into the generator brush holder.

(b) Install the generator brush holder with the 2 screws.
Torque: 1.76 Nm (15 kgf-cm, 16 in-lbf)
(c) Pull the 1.0 mm (0.039 in.) pin out of the generator brush holder.

(d) Install the terminal insulator onto the generator rectifier end frame.

(e) Install the generator rear end cover with the 3 nuts.
Torque: 4.6 Nm (45 kgf-cm, 41 in-lbf)
3. REMOVE GENERATOR PULLEY

SST: 09820-63011
09820-06010
SST: 09820-06021
(a) Install the generator pulley onto the generator rotor shaft, and then temporarily tighten the generator pulley nut by hand.

(b) Tighten SST 1-B to the specified torque, and then fix SST 1-A on the generator rotor shaft.

Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
NOTE: Securely fix SST on the generator rotor shaft.

(e) Turn SST 1-A in the direction shown, and then loosen the generator pulley nut.
Torque: 110.3 Nm (1,125 kgf-cm, 82 ft-lbf)
(f) Remove the generator from SST 2.

(g) Fix SST 1-B, then loosen SST 1-A in the direction shown. Remove SST 1-A and B from the generator.
(h) Turn the generator pulley, and then check that the generator pulley moves smoothly.