Charging (3MZ-FE): Generator: Reassembly

1. Remove the 4 screws, and remove the retainer plate.
   Fig 1: Removing Retainer Plate

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2. Using SST, tap out the bearing.

Fig 2: Removing Generator Drive End Frame Bearing

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

1. Using SST and a press, press in a new bearing.
   Fig 3: Installing Generator Drive End Frame Bearing

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2. Install the retainer plate with the 4 screws.
   Fig 4: Installing Retainer Plate

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   Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf) 

   SST 09950-60010 (09951-00470), 09950-70010 (09951-07100) 

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

Fig 5: Installing Generator Rotor And Generator Washer

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1. 100A Generator
   1. Using deep socket wrench 21 and a press, press in the coil carefully.
2. 130A Generator
   1. Using deep socket wrench 20 and a press, press in the coil carefully.
   Fig 6: Installing Generator Coil Assembly

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3. Tighten the 4 bolts.
   Fig 7: Tightening Bolts

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

1. 100A Generator
   1. While pushing the 2 brushes to inside the brush holder, insert a pin (1.0 mm (0.039 in.)) into the brush holder hole.
      Fig 8: 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 (1.0 mm (0.039 in.)) from the generator brush holder.
   Fig 9: Pulling Out Pin From Generator Brush Holder

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2. 130A Generator
   1. Install the generator plate seal (inside).
   2. Place the generator brush holder with the pin facing upward.
      Fig 10: Placing Generator Brush Holder With Pin Facing Upward

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      NOTE: Be careful of the generator brush holder installing direction.
   3. Tighten the 2 screws.

      Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) 

   4. Align the pins of the generator brush holder with the holes of the generator plate seal (outside), and install the generator plate seal (outside).

1. Install the terminal insulator.

Fig 11: Installing Terminal Insulator

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1. Install the generator 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) 

Fig 12: Installing Generator Rear End Cover

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1. Install the generator pulley to the rotor shaft by tightening the generator pulley nut by hand.
2. Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise with the specified torque.
   Fig 13: Holding SST 1-A With Torque Wrench And Tightening SST 1-B Clockwise

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   Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

   NOTE: Check that SST is secured to the rotor shaft.
3. Clamp SST 2 in a vise.
4. Insert SST 1-A and B into SST 2, and attach the generator pulley nut to SST 2
   Fig 14: Inserting SST 1-A And B Into SST 2

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5. Tighten the generator pulley nut by turning SST 1-A in the direction shown in the illustration.

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

6. Remove the generator from SST 2.
   Fig 15: Tightening Generator Pulley Nut

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7. Turn SST 1-B, and remove SST 1-A, B.
8. Turn the generator pulley, and check that the generator pulley moves smoothly.

Fig 16: Turning SST 1-B, And Removing SST 1-A, B

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