Section 21 (Charging System (2TR-FE)): Generator: Reassembly

1. Place the drive end frame on the generator rotor assembly.
   NOTE: Do not drop the generator rotor assembly.
2. Install the generator rotor assembly and plate retainer.
3. Using a 17 mm socket wrench and press, slowly press in the rectifier end frame.
   Fig 1: Installing Rectifier End Frame Using Socket Wrench & Press

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4. Install the 4 nuts.

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

5. Install the 3 terminal insulators to the rectifier end frame.
   Fig 2: Installing Terminal Insulators To Rectifier End Frame

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1. Install the generator rectifier holder with the 3 screws.

   Torque: 2.0 N*m (20 kgf*cm, 17 in.*lbf) 

   Fig 3: Installing Generator Rectifier Holder With Screws

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1. Install the generator regulator assembly with the 2 screws.

   Torque: 2.0 N*m (20 kgf*cm, 17 in.*lbf) 

   Fig 4: Installing Generator Regulator Assembly With Screws

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1. Install the plate seal.
2. Install the generator brush holder assembly with the 3 screws.

   Torque: 2.0 N*m (20 kgf*cm, 17 in.*lbf) 

3. Install the brush cover on the generator brush holder assembly.
4. Install the rear end cover with the 2 nuts.

   Torque: 4.4 N*m (45 kgf*cm, 39 in.*lbf) 

5. Install the rectifier plate with the nut and screw.

   Torque: 4.4 N*m (45 kgf*cm, 39 in.*lbf) for nut 

   Torque: 3.9 N*m (40 kgf*cm, 34 in.*lbf) for bolt 

6. Install the terminal insulator with the nut.

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

   Fig 5: Identifying Generator Brush Holder Assembly Nuts

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SST 09820-63010 (09820-06010, 09820-06020) 

HINT:

Fig 6: Installing Generator Pulley

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

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

   NOTE: Check that the SST is secured to the generator rotor shaft.
3. Mount SST 2 in a vise.
4. Insert SST 1-A and B into SST 2, and attach the generator pulley nut to SST 2.
   Fig 7: Inserting SST 1-A And B Into SST 2

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5. Tighten the generator pulley nut by turning SST 1-A in the direction shown in Fig 8.

   Torque: 137 N*m (1,397 kgf*cm, 101 ft.*lbf) 

6. Remove the generator from SST 2.
   Fig 8: Tightening Generator Pulley Nut

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7. Turn SST 1-B, and remove SST 1-A and B.
8. Turn the generator pulley, and check that the generator pulley moves smoothly.
   Fig 9: Removing SST 1-A And B

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