Charging System: Generator: Reassembly

1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
3. Install the generator washer.
   Fig 1: Installing Generator Rotor

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1. Using a 21 mm deep socket wrench and press, carefully press in the rectifier end frame.
   Fig 2: Installing Rectifier End Frame

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2. Tighten the 4 bolts.

   Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf) 

   Fig 3: Identifying Rectifier End Frame Bolts

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1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
2. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.

   SST 09820-63011

   Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

3. Check that SST (A) is secured to the pulley shaft.
   Fig 4: Installing Generator Pulley (1 Of 4)

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4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C) to attach the pulley nut to SST (C).
   Fig 5: Installing Generator Pulley (2 Of 4)

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6. Tighten the pulley nut by turning SST (A) in the direction as shown.

   Torque: 110.3 N.m (1,125 kgf.cm, 81 ft.lbf) 

7. Remove the generator from SST (C).
   Fig 6: Installing Generator Pulley (3 Of 4)

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8. Turn SST (B) and remove SST (A and B).
   Fig 7: Installing Generator Pulley (4 Of 4)

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9. Place the brush holder on the rectifier end frame with the pin facing upward.
10. Install the 2 screws.

    Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf) 

    Fig 8: Installing Brush Holder

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1. Install the terminal insulator.
   NOTE: Be careful of the insulator's installation direction.
   Fig 9: Installing Terminal Insulator

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2. Install the end cover with the 3 nuts.

   Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf) 

   Fig 10: Identifying End Cover Nuts

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Check that the rotor rotates smoothly.