1ZR-FE BATTERY / CHARGING GENERATOR REASSEMBLY
PROCEDURE
27310B
1.INSTALL GENERATOR DRIVE END FRAME BEARING
Using SST and a press, install a new generator drive end frame bearing.
- SST
- 09950-60010 (09951-00470)
09950-70010 (09951-07100)
| *a | Tab |
| *b | Cutout |
Fit the tabs of the retainer plate into the cutouts of the generator drive end frame assembly to install the retainer plate.
Install the 4 screws.
- Torque:
- 2.3 N*m (23 kgf*cm, 20 in.*lbf)
27330
2.INSTALL GENERATOR ROTOR ASSEMBLY
Place the generator drive end frame assembly on the generator pulley.
Install the generator rotor assembly to the generator drive end frame assembly.
27360
3.INSTALL GENERATOR COIL ASSEMBLY
| *a | Protrusion |
| *b | Groove |
Install a new bearing cover packing.
- NOTICE:
-
Align the protrusions of the bearing cover packing with the grooves of the generator coil assembly when installing.
Using SST and a press, slowly press the generator coil assembly to install it.
- SST
- 09612-70100 (09612-07240)
Install the 4 bolts.
- Torque:
- 5.6 N*m (57 kgf*cm, 50 in.*lbf)
27370A
4.INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
| *a | Pin (1.0 mm) |
While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder assembly hole.
| *a | Pin (1.0 mm) |
Install the generator brush holder assembly to the generator coil assembly with the 2 screws.
- Torque:
- 1.8 N*m (18 kgf*cm, 16 in.*lbf)
Pull out the pin from the generator brush holder assembly hole.
27387B
5.INSTALL GENERATOR TERMINAL INSULATOR
Install the generator terminal insulator to the generator coil assembly.
- NOTICE:
-
Be sure to install the generator terminal insulator in the correct direction.
27039
6.INSTALL GENERATOR REAR END COVER
Install the generator rear end cover to the generator coil assembly with the 3 bolts.
- Torque:
- 4.6 N*m (47 kgf*cm, 41 in.*lbf)
27411
7.INSTALL GENERATOR PULLEY
Install the generator pulley to the rotor shaft by tightening the nut by hand.
| *a | Turn |
| *b | Hold |
Hold SST 1-(A) with a torque wrench, and tighten SST 1-(B) clockwise to the specified torque.
- SST
- 09820-63011 (09820-06010, 09820-06021)
- Torque:
- 39 N*m (398 kgf*cm, 29 ft.*lbf)
| Item | Part No. |
|---|---|
| SST 1-(A) and 1-(B) | 09820-06010 |
| SST 2 | 09820-06021 |
- NOTICE:
-
Check that SST is secured to the rotor shaft.
Secure the generator assembly in a vise between aluminum plates.
| *a | Turn |
| *b | Hold |
Place the rotor shaft end into SST 1-(A) and 1-(B).
Fit SST 2 to the generator pulley.
Tighten the nut, then turn SST 1-(A) and 1-(B) as shown in the illustration.
- Torque:
- 133 N*m (1356 kgf*cm, 98 ft.*lbf)
- NOTICE:
- ·
Check that the generator drive end frame assembly is secured in the vise tightly.
·Hold SST 2 tightly during the operation.
Remove SST 2 from the generator assembly.
Remove the generator assembly from the vise.
| *a | Turn |
| *b | Hold |
While holding SST 1-(B), turn SST 1-(A) and remove SST 1-(A) and 1-(B).
Turn the generator pulley and check that the generator pulley moves smoothly.