Reassembly (from 07/2011)
1NZ-FE BATTERY / CHARGING: GENERATOR (for Hatchback): REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSEMBLY
(a) Place the generator rotor assembly on the generator drive end frame assembly.
(b) Using a plastic hammer, install the generator rotor assembly to the generator drive end frame assembly.
(c) Install a new generator washer on the generator rotor assembly.
(d) Using a 30 mm/12 pt socket wrench and press, slowly press in the generator rectifier end frame.
Text in Illustration
(e) Install the 3 nuts A.
Torque : 4.5 Nm (46 kgf-cm, 40 in-lbf)
(f) Install the 3 terminal insulators onto the generator rectifier end frame.
(g) Install the cord clip with the nut B.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
Text in Illustration
2. INSTALL GENERATOR HOLDER WITH RECTIFIER
(a) Install the generator holder with rectifier with the 3 screws.
Torque : 2.0 Nm (20 kgf-cm, 18 in-lbf)
3. INSTALL GENERATOR REGULATOR ASSEMBLY
(a) Install the generator regulator assembly with the 2 screws.
Torque : 2.0 Nm (20 kgf-cm, 18 in-lbf)
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
(a) Install the generator plate seal.
(b) Install the generator brush holder assembly with the 3 screws.
Torque : 2.0 Nm (20 kgf-cm, 18 in-lbf)
(c) Install the generator brush cover onto the generator brush holder assembly.
Text in Illustration
(d) Install the generator rear end cover with the 2 nuts B.
Nut B - Torque : 4.4 Nm (45 kgf-cm, 39 in-lbf)
(e) Install the rectifier plate with the nut A and screw.
Nut A - Torque : 4.4 Nm (45 kgf-cm, 39 in-lbf)
Screw - Torque : 3.9 Nm (40 kgf-cm, 35 in-lbf)
Text in Illustration
5. INSTALL GENERATOR TERMINAL INSULATOR
(a) Install the generator terminal insulator with the nut.
Torque : 4.1 Nm (42 kgf-cm, 36 in-lbf)
6. INSTALL GENERATOR PULLEY
(a) Clamp the generator housing stay in a vise tightly.
(b) Install the generator pulley onto the generator rotor shaft by tightening the generator pulley nut by hand.
(c) Hold SST1-A with a torque wrench, and tighten SST1-B clockwise to the specified torque.
SST : 09820-63011
09820-06010
09820-06021
Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)
Text in Illustration
NOTICE:
Check that SST is securely fitted onto the generator rotor shaft.
(d) Insert SST2, and engage SST2 to the pulley nut.
(e) Tighten the generator pulley nut by turning SST1-A in the direction shown in the illustration.
Text in Illustration
Torque : 133 Nm (1356 kgf-cm, 98 ft-lbf)
HINT
Hold the adjustable wrench against the vise and tighten the nut securely.
(f) Remove SST 2 from the generator assembly.
(g) Hold SST1-A, turn SST1-B, and remove SST1-A and SST1-B from the generator assembly.
Text in Illustration
(h) Turn the generator pulley, and check that the generator pulley moves smoothly.
(i) Remove the generator assembly from a vise.