GENERATOR(for TMC Made Cold Area Specification Vehicles) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01VFWSE01

      Using SST and a press, press in a new generator drive end frame bearing.

      SST
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07100 )
    2. A01VGYJE01
      Text in Illustration
      *1 Tab
      *2 Cutout

      Fit the tabs of the retainer plate into the cutouts on the generator drive end frame to install the generator retainer plate.

    3. Install the 4 screws.

      Torque:
      2.3 N*m  { 23 kgf*cm, 20 in.*lbf }

  2. INSTALL GENERATOR ROTOR ASSEMBLY


    1. Place the drive end frame on the clutch pulley.

    2. A01VH9E

      Install the generator rotor assembly to the drive end frame.

    3. A01VM2T

      Place the new generator washer on the generator rotor.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01VIQJE01
      Text in Illustration
      *1 21 mm Socket Wrench

      Using a 21 mm socket wrench and press, slowly press in the generator coil assembly.

    2. Install the 4 bolts.

      Torque:
      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01VEI3E14
      Text in Illustration
      *1 Pin (φ1.0 mm)

      While pushing the 2 brushes into the generator brush holder assembly, insert a φ1.0 mm (0.039 in.) pin into the brush holder hole.

    2. A01VJWX

      Install the brush holder assembly to the generator coil with the 2 screws.

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }
    3. A01VG7W

      Pull out the pin from the generator brush holder.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01VI3Z

      Install the terminal insulator to the generator coil.

      Note

      Pay attention to the installation direction of the terminal insulator as shown in the illustration.

  6. INSTALL GENERATOR REAR END COVER


    1. A01VJMH

      Install the generator rear end cover to the generator coil with the 3 nuts.

      Torque:
      4.6 N*m  { 47 kgf*cm, 41 in.*lbf }

  7. INSTALL GENERATOR CLUTCH PULLEY


    1. Temporarily install the clutch pulley onto the rotor shaft.

    2. Clamp the generator housing stay in a vise.

    3. A01VHO3E03
      Text in Illustration
      *1 Rotor shaft

      Place the rotor shaft end into SST (A).

      SST
      09820-63021
    4. A01VGTIE03
      Text in Illustration
      *1 Clutch Pulley

      Fit SST (B) to the clutch pulley.

    5. A01VISNE03
      Text in Illustration
      *a Turn
      *b Hold
      *c Length 100 mm

      Tighten the pulley by turning SST (B) in the direction shown in the illustration.

      Torque:
      without SST
      111 N*m  { 1127 kgf*cm, 82 ft.*lbf }
      with SST
      84 N*m  { 857 kgf*cm, 62 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).

      • This torque value is effective when SST is parallel to the torque wrench.

    6. Remove SST from the generator.

    7. Check that the clutch pulley rotates smoothly.

    8. Install a new generator clutch pulley cap to the clutch pulley.

  8. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A01VF66

      Install the wire harness clamp bracket with the 2 bolts.

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