Reassembly

2AZ-FE BATTERY / CHARGING: GENERATOR: REASSEMBLY

REASSEMBLY

1. INSTALL GENERATOR DRIVE END FRAME BEARING

(a) Using SST and a press, press in a new generator drive end frame bearing.
SST: 09950-60010
09951-00250
SST: 09950-70010
09951-07100

(b) Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.
(c) Install the 4 screws.
Torque: 2.3 Nm (23 kgf-cm, 20 in-lbf)
2. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Place the drive end frame on the clutch pulley.

(b) Install the generator rotor onto the generator rectifier end frame.

(a) Using SST and a press, press in the generator coil assembly to the drive end frame.
SST: 09612-70100
09612-07240

(b) Tighten the 4 bolts.
Torque: 5.8 Nm (59 kgf-cm, 51 in-lbf)

(c) Install the cord clip with the bolt.
Torque: 4.6 Nm (47 kgf-cm, 41 in-lbf)
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

(a) While pushing the 2 brushes into the generator brush holder, insert a dia1.0 mm (0.0394 in.) pin into the generator brush holder.

(b) Install the generator brush holder with the 2 screws.
Torque: 1.8 Nm (18 kgf-cm, 16 in-lbf)

(a) Install the terminal insulator onto the generator rectifier end frame.
6. INSTALL GENERATOR REAR END COVER

(a) Install the generator rear end cover with the 3 nuts.
Torque: 4.6 Nm (47 kgf-cm, 41 in-lbf)
7. INSTALL GENERATOR CLUTCH PULLEY
(a) Temporarily install the clutch pulley onto the rotor shaft.

(b) Set SST (A) and (B).
SST: 09820-63021

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

(f) Tighten the pulley by turning SST (B) in the direction indicated by the arrow shown in the illustration.
Without SST - Torque: 111 Nm (1127 kgf-cm, 82 ft-lbf)
With SST - Torque: 84 Nm (857 kgf-cm, 62 ft-lbf)

NOTICE:
- Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).
- This torque value is effective when SST is parallel to the torque wrench.

(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.