Reassembly

3MZ-FE CHARGING: GENERATOR:

REASSEMBLY

1. INSTALL GENERATOR DRIVE END FRAME BEARING

(a) Using SST and a press, press in a new bearing.
SST: 09950-60010
09951-00470
SST: 09950-70010
09951-07100

(b) Install the 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 and generator washer.
3. INSTALL GENERATOR RECTIFIER END FRAME

(a) Using a 21 mm deep socket wrench and a press, press in the generator rectifier end frame carefully.

(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 brush holder, insert a pin (dia 1.0 mm (0.039 in.)) into the brush holder hole.

(b) Install the generator brush holder 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 rectifier end frame.

NOTE: Pay attention to the mounting orientation of the terminal insulator.

6. INSTALL GENERATOR REAR END COVER

(a) Install the end cover with the 3 nuts.
Torque: 4.6 Nm (47 kgf-cm, 41 in-lbf)
7. INSTALL GENERATOR PULLEY
(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, and tighten SST (1-B) clockwise to the specified torque.
SST: 09820-63010
09820-06010
09820-06020
Torque: 39 Nm (400 kgf-cm, 29 in-lbf)

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

(e) Tighten the pulley nut by turning SST (1-A) in the direction shown in the illustration.
Torque: 110 Nm (1,122 kgf-cm, 81 ft-lbf)
(f) Remove the generator from SST (2).

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