Reassembly

2AR-FE BATTERY / CHARGING: GENERATOR: REASSEMBLY

1. INSTALL GENERATOR DRIVE END FRAME BEARING





(a) Using SST and a press, press in a new bearing.

SST : 09950-60010

09951-00520

SST : 09950-70010

09951-07100





(b) Install the bearing retainer with the 4 screws.

Torque : 2.3 Nm (23 kgf-cm, 20 in-lbf)

2. INSTALL GENERATOR ROTOR ASSEMBLY

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





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

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





3. INSTALL GENERATOR COIL ASSEMBLY

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





Text in Illustration





(b) Install the 4 bolts.

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, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder.





Text in Illustration





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





Torque : 1.8 Nm (18 kgf-cm, 16 in-lbf)

Text in Illustration





(c) Pull the pin out of the generator brush holder.

5. INSTALL GENERATOR REAR END COVER

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

(b) Install the generator rear end cover with the 3 nuts.

Torque : 4.6 Nm (46 kgf-cm, 40 in-lbf)

6. INSTALL GENERATOR PULLEY WITH CLUTCH

(a) Temporarily install the generator pulley by hand.

(b) Mount the generator in a vise.

(c) Install SST (A) and (B) to the generator pulley as shown in the illustration.





SST : 09820-63021

(d) Using a wrench to hold SST (A), turn SST (B) clockwise to tighten the generator pulley.





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

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

Text in Illustration





HINT
* Use a torque wrench with a fulcrum length of 400 mm (15.7 in.). When using a torque wrench with a fulcrum length that is not 400 mm (15.7 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification ( Service Precautions).
* Make sure SST and the wrench are connected in a straight line.

NOTICE:
Be careful as the generator with clutch pulley or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

(e) Check that the generator pulley rotates smoothly.

7. INSTALL GENERATOR PULLEY CAP

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