Charging System: Generator: Reassembly

INSTALL ROTOR TO DRIVE END FRAME 

1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
   Fig 1: Installing Rotor To Drive End Frame (12V 90 A Type)

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INSTALL ROTOR TO DRIVE END FRAME 

1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
   Fig 2: Installing Rotor To Drive End Frame (12V 100 A Type)

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INSTALL RECTIFIER END FRAME 

1. Place the generator washer on the rotor.
   Fig 3: Installing Rectifier End Frame (12V 90 A Type)

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2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
   Fig 4: Pressing In Rectifier End Frame (12V 90 A Type)

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3. Install the wire clip and 4 nuts.

   Torque: 

   4.5 N.m (46 kgf.cm, 40 in.lbf) for without wire clip 5.4 N.m (55 kgf.cm, 48 in.lbf) for with wire clip 

   Fig 5: Installing Wire Clip & 4 Nuts

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INSTALL RECTIFIER END FRAME 

1. Place the alternator washer on the rotor.
   Fig 6: Placing Alternator Washer On Rotor (12V 100 A Type)

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2. Using a 21 mm socket wrench and press, slowly press in the rectifier end frame.
   Fig 7: Identifying 21 MM Socket Wrench (12V 100 A Type)

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3. Tighten the 4 bolts.

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

4. Install the cord clip with the bolt.

   Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf) 

   Fig 8: Tightening 4 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 (398 kgf.cm, 29 ft.lbf) 

3. Check that SST (A) is secured to the pulley shaft.
   Fig 9: Installing Pulley To Rotor Shaft By Tightening Pulley Nut By Hand

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4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
   Fig 10: Mounting SST (C) In Vise

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6. To torque the pulley nut, turn SST (A) in the direction shown in Fig 11.

   Torque: 111 N.m (1,132 kgf.cm, 82 ft.lbf) 

7. Remove the generator from SST (C).
   Fig 11: Removing Generator From SST (C)

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8. Turn SST (B), and remove SST (A and B).
   Fig 12: Removing SST (A & B)

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INSTALL RECTIFIER HOLDER 

1. Install the 4 rubber insulators on the lead wires.
   NOTE: Be careful of the rubber insulators installation direction.
   Fig 13: Installing 4 Rubber Insulators (12V 90 A Type)

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2. Install the rectifier holder while pushing it with the 4 screws.

   Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf) 

   Fig 14: Identifying 4 Screws (12V 90 A Type)

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INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER 

1. Place the seal plate on the rectifier end frame.
   Fig 15: Placing Seal Plate On Rectifier End Frame (12V 90 A Type)

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2. Place the voltage regulator and brush holder on the rectifier end frame.
   NOTE: Be careful of the holder installation direction.
3. Install the 5 screws.

   Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf) 

   Fig 16: Installing 5 Screws (12V 90 A Type)

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INSTALL BRUSH HOLDER AND TERMINAL INSULATOR 

1. While pushing the 2 brushes to inside the brush holder, insert a pin (diameter 1.0 mm (0.039 in.)) into the brush holder hole.
   Fig 17: Installing Brush Holder & Terminal Insulator (12V 100 A Type)

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2. Install the brush holder with the 2 screws.

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

3. Pull out the pin (diameter 1.0 mm (0.039 in.)) from the brush holder.
   Fig 18: Installing Brush Holder With 2 Screws (12V 100 A Type)

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4. Install the terminal insulator to the rectifier end frame.
   Fig 19: Installing Terminal Insulator To Rectifier End Frame (12V 100 A Type)

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INSTALL REAR END COVER 

1. Place the brush holder cover on the brush holder.
   Fig 20: Placing Brush Holder Cover On Brush Holder (12V 90 A Type)

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2. Install the end cover and plate terminal with the bolt and 3 nuts.

   Torque: 

   4.4 N.m (45 kgf.cm, 39 in.lbf) for nut 3.9 N.m (40 kgf.cm, 35 in.lbf) for bolt 

   Fig 21: Installing End Cover & Plate Terminal With Bolt & 3 Nuts (12V 90 A Type)

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3. Install the terminal insulator with the nut.

   Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf) 

   Fig 22: Installing Terminal Insulator With Nut (12V 90 A Type)

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INSTALL REAR END COVER 

Install the end cover with the bolt and 3 nuts.

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