Reassembly

2GR-FE BATTERY / 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.

Text in Illustration:

SST : 09820-63021

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

Text in Illustration:

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

Text in Illustration:

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

Text in Illustration:

without SST - Torque : 111 Nm (1132 kgf-cm, 82 ft-lbf)

with SST - Torque : 89 Nm (908 kgf-cm, 66 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 318 mm (1.04 ft.).
* This torque value is effective when SST is parallel to the torque wrench.
* Check that the drive end frame is secured in the vise tightly.
* Hold SST (A) tightly during the operation.
(g) Remove the generator assembly from SST.

(h) Check that the clutch pulley rotates smoothly.

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

3. INSTALL GENERATOR COIL ASSEMBLY

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

Text in Illustration:

(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 into the generator brush holder assembly, insert a dia1.0 mm (0.0394 in.) pin into the brush holder hole.

Text in Illustration:

(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.

Text in Illustration:

5. INSTALL GENERATOR TERMINAL INSULATOR

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

NOTICE:
Be sure to install the terminal insulator in the correct direction.

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)