GENERATOR(for TMC Made except Cold Area Specification Vehicles) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR ROTOR ASSEMBLY


    1. Place the generator drive end frame on the generator rotor assembly.

      Note

      Do not drop the generator rotor assembly.

    2. Install the generator rotor assembly and plate retainer.

    3. A01VLF3E01
      Text in Illustration
      *1 30 mm Socket Wrench

      Using a 30 mm socket wrench and press, slowly press in the rectifier end frame.

    4. A01VFMM

      Install the 4 nuts.

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }

    5. Install the 3 terminal insulators onto the rectifier end frame.

  2. INSTALL GENERATOR HOLDER WITH RECTIFIER

    A01VJKT

    1. Install the generator rectifier holder with the 3 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 17 in.*lbf }

  3. INSTALL GENERATOR REGULATOR ASSEMBLY

    A01VK2F

    1. Install the generator regulator assembly with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 17 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

    A01VKI9

    1. Install the plate seal.

    2. Install the generator brush holder assembly with the 3 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 17 in.*lbf }

    3. Install the brush cover onto the generator brush holder assembly.

    4. Install the rear end cover with the 2 nuts.

      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }

    5. Install the rectifier plate with the nut and screw.

      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }
      for nut
      Torque:
      3.9 N*m  { 40 kgf*cm, 34 in.*lbf }
      for screw

    6. Install the terminal insulator with the nut.

      Torque:
      4.1 N*m  { 42 kgf*cm, 36 in.*lbf }

  5. INSTALL GENERATOR PULLEY

    A01VFE1E06

    Tech Tips

    SST 1-A and B 09820 - 06010
    SST 2 09820 - 06021
    Text in Illustration
    *a Turn
    *b Hold

    1. Clamp the generator housing stay in a vise.

    2. Install the generator pulley onto the generator rotor shaft by tightening the generator pulley nut by hand.

    3. 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 }

      Note

      Check that SST is securely fitted onto the generator rotor shaft.

    4. A01VLCTE05

      Insert SST 2, and attach the pulley nut to SST 2.

    5. A01VL0PE02
      Text in Illustration
      *a Hold
      *b Turn

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

      Torque:
      133 N*m  { 1356 kgf*cm, 98 ft.*lbf }

      Tech Tips

      Hold the adjustable wrench against the vise and tighten the nut securely.

    6. Remove SST 2 from the generator.

    7. A01VF8SE07
      Text in Illustration
      *a Turn
      *b Hold

      Turn SST 1-B, and remove SST 1-A and B.

    8. Turn the generator pulley, and check that the generator pulley moves smoothly.

  6. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A01VK4U

      Install the wire harness clamp bracket with the 2 bolts.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }