Repair Procedures: Reassembly: Mounting

Mount the rotor on the front housing.
Install the four through bolts after mounting the rear housing.
Tightening torque:

4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)
NOTE:
- Make sure that the wave washer (B) is inserted between the rear housing and the slip ring (A).
- Do not hit the rear housing with a hammer when mounting it.
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Insert the brush (A) into the brush holder and then insert the fixing pin (B) into the mounting hole (C) to fix the brush (A).

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NOTE:
- Be sure to remove the fixing pin after mounting the brush holder on the snap ring. Make sure that the removed fixing pin does not get inside the alternator.
Install the brush holder.
NOTE:
- Slightly press the brush holder assembly with the fixing pin inserted inside the level frame, until the seating surface of the brush holder assembly is firmly latched.
- Be careful not to damage the slip ring when mounting the brush.
Tightening torque:

1.6 - 1.9 N.m (0.16 - 0.2 kgf.m, 1.2 - 1.4 lb-ft)
Remove the brush fixing pin.
Mount the rear cover.
Tightening torque:

3.8 - 5.3 N.m (0.39 - 0.54 kgf.m, 2.8 - 3.9 lb-ft)
NOTE:
- Do not apply impact to the rear cover, B terminal, and bush when mounting the rear cover.
Mount the bush on the B terminal.
Insert an aluminum plate and fix the alternator on the vise.
NOTE:
- Fixing the alternator housing may damage the stator coil. Therefore, tighten the fixing bolts on the front and rear housings instead.
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Mount the pulley (A) and tighten the pulley nut (B) temporarily.

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Mount a special tool (A) (SST No.: 09373-F3100) on the pulley mounting nut (B).
Tightening torque:

35.3 - 43.1 N.m (3.6 - 4.4 kgf.m, 26.0 - 31.8 lb-ft)

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NOTE:
- Insert the special tool (A) into the pulley nut completely and tighten it.
Install a wrench (A) so that its end touches the workbench (B).

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NOTE:
- Be sure to use a wrench long enough to touch the workbench and fix it on the workbench.
- A lot of force is applied to the wrench when you use the standard torque. Make sure that the wrench does not slip from its position.
With the special tool (A) fixed by the wrench (B), insert a torque wrench (C) to the rotor shaft and tighten it in the (D) direction.
Tightening torque:

128.1 - 137.1 N.m (13.06 - 13.98 kgf.m, 94.5 - 101.1 lb-ft)

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NOTE:
- Tighten the torque wrench (C) while pushing the wrench (B) so that the wrench (B) does not move.