Charging System (3MZ-FE): Generator: Reassembly

1. Place the drive end frame on the pulley.
2. Install the rotor and washer.
   Fig 1: Identifying Rotor And Washer

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1. Using deep socket wrench 21 and a press, press in the coil carefully.
   Fig 2: Pressing Coil

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2. Tighten the 4 bolts.

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

   Fig 3: Locating Bolts

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1. While pushing the 2 brushes to the inside of the brush holder, insert a pin (ø 1.0 mm (0.039 in.)) into the brush holder hole.
   Fig 4: Identifying 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 (ø 1.0 mm (0.039 in.)) from the generator brush holder.
   Fig 5: Locating Generator Brush Holder And Screws

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1. Install the terminal insulator.
   NOTE: Pay attention to the mounting direction of the terminal insulator.
   Fig 6: Identifying 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) 

   Fig 7: Locating Rear End Cover And Nuts

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

HINT:

1. Install the 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 to the specified torque.

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

   NOTE: Check that SST is secured to the rotor shaft.
   Fig 8: Holding SST (1-A) With Torque Wrench

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3. Mount SST (2) in a vise.
4. Insert SST (1-A) and (1-B) into SST (2), and attach the generator pulley nut to SST (2).
   Fig 9: Inserting SST (1-A) And (1-B) Into SST

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

   Torque: 133 N*m (1351 kgf*cm, 98 ft.*lbf) 

   Fig 10: Turning SST (1-A)

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6. Remove the generator from SST (2).
7. Turn SST (1-B), and remove SST (1-A) and (1-B).
8. Turn the pulley, and check that the pulley moves smoothly.
   Fig 11: Turning SST (1-B)

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