Disassembly and Reassembly

OVERHAUL
1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)

(a) Hold SST 1-A with a torque wrench, then tighten SST 1-B clockwise with the specified torque.
Torque: 39 N-m (400 kgf-cm, 29 ft-lbf)

NOTICE: Check that SST is secured to the rotor shaft.

(b) Clamp SST 2 in a vise.
(c) Insert SST 1-A and B into SST 2, then attach the pulley nut to SST 2.

(d) To loosen the pulley nut, turn SST 1-A in the direction shown in the illustration.

NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than a half turn.

(e) Remove the generator from SST 2.

(f) Turn SST 1-B, then remove SST 1-A and B.
(g) Remove the pulley nut, then remove the generator pulley.

2. REMOVE GENERATOR BRUSH HOLDER ASSY
(a) Remove the nut, then remove the terminal insulator.
(b) Remove the screw and nut, then remove the terminal plate.
(c) Remove the 2 nuts, then remove the rear end cover.
(d) Remove the generator brush cover from the generator brush holder.
(e) Remove the 2 screws, then remove the generator brush holder.
(f) Remove the generator plate seal from the generator rectifier end frame.

3. REMOVE GENERATOR REGULATOR ASSY
(a) Remove the 3 screws, then remove the generator regulator.

4. REMOVE GENERATOR HOLDER WIRECTIFIER
(a) Remove the 4 screws, then remove the generator holder wi rectifier.

5. REMOVE GENERATOR RECTIFIER END FRAME
(a) Remove the 4 terminal insulators from the generator rectifier end frame.
(b) Remove the 4 nuts and generator cord clip.
(c) Using SST, remove the generator rectifier end frame. ssT 09286-46011

6. REMOVE GENERATOR ROTOR ASSY
(a) Remove the generator washer from the generator rotor.
(b) Remove the generator rotor from the generator drive end frame.

7. INSPECT GENERATOR BRUSH HOLDER ASSY
(a) Inspect the brush length.
(1) Using vernier calipers, measure the exposed brush length.
Standard exposed brush length: 9.5 to 11.5 mm (0.374 to 0.453 in.)
Minimum exposed brush length: 1.5 mm (0.059 in.)
If the exposed brush length is less than minimum, replace the generator brush holder.

8. INSPECT GENERATOR REGULATOR ASSY
(a) Check the continuity.

(1) Using an ohmmeter, check for continuity between terminals F and B.
Standard: When the positive and negative poles between terminals F and B are exchanged, there is continuity in one way but no continuity in another way.
If the result is not as specified, replace the generator regulator.

(2) Using an ohmmeter, check for continuity between terminals F and E.
Standard: When the positive and negative poles between terminals F and E are exchanged, there is continuity in one way but no continuity in another way.
If the result is not as specified, replace the generator regulator.

9. INSPECT GENERATOR HOLDER W/RECTIFIER

(a) Check the continuity.

(1) Using an ohmmeter; connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.
(2) Reverse the polarity of the tester probes, then repeat step (1).
(3) Check that one shows continuity and the other shows no continuity.
If the result is not as specified, replace the generator holder w/rectifier.

(4) Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal.
(5) Reverse the polarity of the tester probes, then repeat step (4).
(6) Check that one shows continuity and the other shows no continuity.
If the result is not as specified, replace the generator holder w/rectifier.

10. INSPECT GENERATOR ROTOR ASSY

(a) Check for rough or wear.
(1) Check that the bearing is not rough or worn.
^ If necessary, replace the bearing. (1ZZ-FE ENGINE TYPE)
^ If necessary, replace the generator rotor. (2ZZ-GE ENGINE TYPE)

(b) Inspect the resistance.
(1) Using an ohmmeter, check the resistance between the slip rings.
Standard resistance: 2.1 to 2.5 ohms at 20°C (68°F)
If the resistance is not as specified, replace the generator rotor.

(c) Check the continuity.
(1) Using an ohmmeter, check that there is no continuity between the slip ring and rotor core.
If there is continuity replace the generator rotor.

(d) Check for rough or score.
(1) Check that the slip rings are not rough or scored. If rough or scored, replace the generator rotor.

(e) Inspect the slip ring diameter.
(1) Using vernier calipers, measure the slip ring diameter.
Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the generator rotor.

11. INSPECT GENERATOR RECTIFIER END FRAME

(a) Check for rough or wear.
(1) Check that the bearing is not rough or worn.
^ If necessary, replace the bearing. (1ZZ-FE ENGINE TYPE)
^ If necessary, replace the generator drive end frame. (2ZZ-GE ENGINE TYPE)

(b) Check the continuity.
(1) Using an ohmmeter, check that there is continuity between the coil leads.
If there is no continuity, replace the generator drive end frame.

(2) Using an ohmmeter, check that there is no continuity between the coil lead and body.
If there is continuity, replace the generator drive end frame.

12. REMOVE GENERATOR ROTOR BEARING (1ZZ-FE ENGINE TYPE)
(a) Clamp the generator rotor in a vise.

(b) Using SST remove the generator bearing cover (outside) and bearing.
SST 09820-00021

NOTICE: Be careful not to damage the fan.

(c) Remove the generator bearing cover (inside) from the generator rotor.

13. INSTALL GENERATOR ROTOR BEARING (1ZZ-FE ENGINE TYPE)
(a) Place the generator rotor on the generator pulley.
(b) Install the generator bearing cover (inside) to the generator rotor.

(d) Using SST push in the generator bearing cover (outside).
SST 09285-76010

14. REMOVE GENERATOR DRIVE END FRAME BEARING (1ZZ-FE ENGINE TYPE)

(a) Remove the 4 screws, then remove the retainer plate.

(b) Using SST and a press, press out the bearing.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07100)

15. INSTALL GENERATOR DRIVE END FRAME BEARING (1ZZ-FE ENGINE TYPE)
(a) Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07100)

(b) Install the retainer plate with the 4 screws.
Torque: 3.0 N-m (31 kgf-cm, 27 in.-lbf)

16. INSTALL GENERATOR ROTOR ASSY
(a) Place the generator drive end frame on the generator pulley.
(b) Install the generator rotor to the generator drive end frame.
(c) Install the generator washer to the generator rotor.

17. INSTALL GENERATOR RECTIFIER END FRAME

(a) Using a socket wrench 29 and a press, slowly press in the generator rectifier end frame.

(b) Install the generator cord clip and 4 nuts.
Torque:
4.5 N-m (46 kgf-cm, 40 in.-lbf) for nut A
5.4 N-m (55 kgf-cm, 48 in.-lbf) for nut B

(c) Install the 4 terminal insulators to the generator rectifier end frame.

18. INSTALL GENERATOR HOLDER WIRECTIFIER
(a) Install the generator holder wi rectifier with the 4 screws.
Torque: 2.9 N-m (30 kgf-cm, 26 in.-lbf)

19. INSTALL GENERATOR REGULATOR ASSY
(a) Install the generator regulator with the 3 screws.
Torque: 2.0 N-m (20 kgf-cm, 18 in.-lbf)

20. INSTALL GENERATOR BRUSH HOLDER ASSY
(a) Install the generator plate seal to the generator rectifier end frame.
(b) Install the generator brush holder with the 2 screws.
Torque: 2.0 N-m (20 kgf-cm, 18 in.-lbf)

NOTICE: Pay attention to the generator brush holder installation direction.

(c) Install the generator brush cover to the generator brush holder.
(d) Install the generator rear and cover with the 2 nuts.
Torque: 4.4 N-m (45 kgf-cm, 39 in.-lbf)

(e) Install the terminal plate.
Torque:
3.9 N-m (40 kgf-cm, 35 in.-lbf) for bolt
4.4 N-m (45 kgf-cm, 39 in.-lbf) for nut

(f) Install the terminal insulator with the nut.
Torque: 4.1 N-m (42 kgf-cm, 36 in.-lbf)

21. INSTALL GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)

(a) Install the generator pulley to the rotor shaft by tightening the pulley nut by hand.
(b) Hold SST 1-A with a torque wrench, then tighten SST 1-B clockwise with the specified torque.
Torque: 39 N-m (400 kgf-cm, 29 ft-lbf)

NOTICE: Check that SST is secured to the rotor shaft.

(e) Tighten the pulley nut, turn SST 1-A toward the direction shown in the illustration.
Torque: 111 N-m (1,132 kgf-cm, 82 ft-lbf)

(f) Remove the generator from SST 2.

(g) Turn SST 1-B, then remove SST 1-A and B.
(h) Turn the generator pulley, then check that the generator pulley moves smoothly.