Charging System (1GR-FE): Generator: Reassembly

1. Using SST and a press, press in a new bearing.

   SST 09950-60010 (09951-00250), 09950-70010 (09951-07100) 

2. Install the retainer plate with the 4 screws.

   Torque: 2.2 N*m (22 kgf*cm, 19 in.*lbf) 

   Fig 1: Installing Generator Drive End Frame Bearing

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1. Place the drive end frame on the rotor.
2. Install the rotor and washer.

1. Using a deep socket wrench 21 and a press, in the generator rectifier end frame carefully.
   Fig 2: Using Deep Socket Wrench And Press

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2. Install the 4 bolts.

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

   Fig 3: Installing Generator Coil Bolts

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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 4: Inserting Pin Into 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 (diameter 1.0 mm (0.039 in.)) from the generator brush hold.

Fig 5: Pulling Out Pin From Generator Brush Hold

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1. Install the terminal insulator to the generator rectifier end frame.
   NOTE: Pay attention the mounting orientation of the terminal insulator.

Fig 6: Installing Terminal Insulator

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1. Install the rear end cover with the 3 nuts.

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

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

HINT:

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 (400 kgf*cm, 29 ft.*lbf) 

   Fig 7: Tightening SST 1-B Clockwise

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   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 8: Inserting SST 1-A & B Into SST 2

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5. Tighten the pulley nut by turning SST 1-A in the direction shown in Fig 9.

   Torque: 111 N*m (1,125 kgf*cm, 81 ft.*lbf) 

   Fig 9: 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.
   Fig 10: Turning SST 1-B

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8. Turn the pulley and check that the pulley moves smoothly.