Section 1 (Engine Starting System & Charging System (3.6L)): Generator: Assembly

WARNING: This page is about a different variant/trim than selected.

NOTE: After assembling, manually turn the pulley to check that the rotor rotates smoothly.

When the rectifier is removed

Apply grease to the mating surface of the rear cover and the rectifier as shown in the figure.

CAUTION: Do not apply grease to the attachment threads of the rectifier.

Grease:

Silicone oil compound for heat radiation YG6240 or equivalent

Amount of grease application (one place):

Approx. 0.14 g

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Install the rectifier.

Tightening torque:

3.9 N.m (0.4 kgf-m, 2.9 ft-lb)

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Install the terminal B.

Tightening torque:

8.9 N.m (0.9 kgf-m, 6.6 ft-lb)

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Install the cap to the terminal B.

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When the brush is removed

Set the brush and solder the connection.

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Install the cover B.

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Install the cover A.

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When the ball bearing is removed

Set the ball bearings in the front cover, then set an appropriate tool (such as a socket wrench of proper size) for the bearing outer race.
CAUTION:
- Do not apply grease to the ball bearings.
- If any grease adheres to the ball bearing attachment area, remove it completely.
NOTE: Use a new ball bearing.
Using a press, install the ball bearings.

Install the bearing retainer.

NOTE: If necessary, use a vise to secure the front cover.

Tightening torque:

3.9 N.m (0.4 kgf-m, 2.9 ft-lb)

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Using a press, install the bearings to the rotor shaft.
NOTE: Use a new bearing.
Install the rotor to the front cover.
NOTE: Check that the spacer is installed to the rotor.

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Hold the rotor on a vise and install the pulley.
CAUTION:
- Place aluminum plates or wooden pieces into the contacting surfaces between the vise and the rotor to prevent rotor damage.
- Do not tighten the vise more than necessary.
Tightening torque:

117.5 N.m (12.0 kgf-m, 86.7 ft-lb)

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Press the brush into the brush holder, then fix the brush by inserting a wire [2 mm (0.08 in) dia., 40 - 50 mm (1.6 - 2.0 in) long] through the service hole of the rear cover.
NOTE: The gasket installed to the IC regulator can be passed through.

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Use a drier to heat the bearing attachment area of the rear cover to 50 - 60°C (122 - 140°F), and install the rotor to the rear cover.
CAUTION:
- Do not apply grease to the bearings.
- If any grease adheres to the bearing attachment area, remove it completely.
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Remove the wire from the service hole of the rear cover.
Install the through bolt.
Tightening torque:

4.4 N.m (0.4 kgf-m, 3.2 ft-lb)

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