Reassembly

1ZZ-FE CHARGING: GENERATOR:

COMPONENTS

REASSEMBLY

1. INSTALL GENERATOR ROTOR ASSEMBLY

(a) Place the generator drive end frame on the generator pulley.
(b) Install the generator rotor onto the generator drive end frame.
(c) Install the generator washer onto the generator rotor.
2. INSTALL GENERATOR RECTIFIER END FRAME

(a) Using a socket wrench 29 and a press, slowly push the generator rectifier end frame in.

(b) Install the generator cord clip and 4 nuts.
Nut A - Torque: 4.5 Nm (46 kgf-cm, 40 in-lbf)
Nut B - Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
(c) Install the 4 terminal insulators onto the generator rectifier end frame.
3. INSTALL GENERATOR HOLDER W/RECTIFIER
(a) Install the generator holder with rectifier with the 4 screws.
Torque: 2.9 Nm (30 kgf-cm, 26 in-lbf)
4. INSTALL GENERATOR REGULATOR ASSEMBLY
(a) Install the generator regulator with the 3 screws.
Torque: 2.0 Nm (20 kgf-cm, 18 in-lbf)
5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

(a) Install the generator plate seal onto the generator rectifier end frame.
(b) Install the generator brush holder with the 2 screws.
Torque: 2.0 Nm (20 kgf-cm, 18 in-lbf)

NOTE: Make sure that the generator brush holder is in the correct direction.

(c) Install the generator brush cover onto the generator brush holder.
(d) Install the generator rear and cover it with the 2 nuts.
Torque: 4.4 Nm (45 kgf-cm, 39 in-lbf)
(e) Install the terminal plate.
Bolt - Torque: 3.9 Nm (40 kgf-cm, 35 in-lbf)
Nut - Torque: 4.4 Nm (45 kgf-cm, 39 in-lbf)
(f) Install the terminal insulator with the nut.
Torque: 4.1 Nm (42 kgf-cm, 36 in-lbf)
6. INSTALL GENERATOR PULLEY
SST: 09820-63010
09820-06010
09820-06020

(a) Install the generator pulley onto the rotor shaft by tightening the pulley nut by hand.
(b) Hold SST 1-A with a torque wrench, then tighten SST 1-B counterclockwise to the specified torque.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)

NOTE: Securely fix SST on the generator rotor shaft.

(e) Tighten the pulley nut, then turn SST 1-A in the direction shown in the illustration.
Torque: 111 Nm (1,132 kgf-cm, 82 ft-lbf)
(f) Remove the generator from SST 2.

(g) Turn SST 1-B, then remove SST 1-A and B.
(h) Turn the generator pulley, then check that the generator pulley moves smoothly.