Charging Systems: Generator: Reassembly

1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
   Fig 1: Identifying Generator Rotor Assembly

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1. Place the generator washer on the rotor.
   Fig 2: Identifying Generator Washer On Rotor

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2. Using a 21 mm socket wrench and a press, slowly press in the coil assembly.
   Fig 3: Identifying Generator Coil Assembly

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3. Install the 4 bolts.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

   Fig 4: Locating Generator Coil Assembly Bolts

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1. While pushing the 2 brushes toward the inside of the brush holder, insert a pin (diameter: 1.0 mm (0.0394 in.)) into the brush holder hole.
   Fig 5: Identifying Pin In Brush Holder Hole

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2. Install the generator brush holder with the 2 screws.

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

3. Pull out the pin from the generator brush holder.
   Fig 6: Identifying Pin

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1. Install the terminal insulator to the generator rectifier end frame.
   NOTE: Pay attention to the mounting orientation of the terminal insulator.
   Fig 7: Identifying Terminal Insulator

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2. Install the end cover with the 3 nuts.

   Torque: 4.6 N*m (46 kgf*cm, 40 in.*lbf) 

   Fig 8: Locating End Cover Nuts

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SST 09820-63011 (09820-06010, 09820-06021) 

HINT:

Fig 9: Installing Pulley Onto Rotor Shaft

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

   Torque: 39 N*m (398 kgf-cm, 29 ft.*lbf) 

   NOTE: Check that SST is secured to the rotor shaft.
3. Mount SST 2 in a vise.
4. Insert SST 1-A and B into SST 2, and attach the pulley nut to SST 2.
   Fig 10: Attaching Pulley Nut To Sst 2

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5. Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.

   Torque: 133 N*m (1351 kgf*cm, 98 ft.*lbf) 

   Fig 11: Tightening Pulley Nut

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6. Remove the generator from SST 2.
7. Turn SST 1-B, and remove SST 1-A and B.
8. Turn the pulley and check that the pulley moves smoothly.
   Fig 12: Checking Pulley Operation

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