GENERATOR(for DENSO Made) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A004AHEE01

      Using SST and a press, press in a new generator drive end frame bearing until the bearing surface is level with the frame surface.

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A0047JEE01
      Text in Illustration
      *a Tab
      *b Cutout

      Install the retainer plate to the generator drive end frame assembly with the 4 screws.

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

  2. INSTALL GENERATOR ROTOR ASSEMBLY


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

    2. A0047YD

      Install the generator rotor assembly to the generator drive end frame assembly.

      Note

      Do not drop the generator rotor assembly.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A00477ZE01
      Text in Illustration
      *a Protrusion
      *b Groove

      Install a new generator bearing cover packing to the generator coil assembly.

      Tech Tips

      Align the 3 protrusions of the generator bearing cover packing with the 3 grooves of the generator coil assembly when installing.

    2. A004BKQ

      Temporarily install the generator coil assembly to the generator drive end frame assembly with the 4 bolts.

      Note

      Because the generator coil assembly must be installed with a press after the through bolts have first been temporarily tightened, do not attempt to install the alternator coil assembly by tightening the through bolts only.

    3. A0049TXE01

      Using SST and a press, slowly press the generator coil assembly to install it.

      SST
      09612-70100   ( 09612-07240 )

    4. Tighten the 4 bolts.

      Torque:
      5.6 N*m  { 57 kgf*cm, 50 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A0049F8E02
      Text in Illustration
      *a 1.0 mm (0.0394 in.) Diameter Pin

      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.

    2. A0047BP

      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 }
    3. A004BHBE02
      Text in Illustration
      *a 1.0 mm (0.0394 in.) Diameter Pin

      Pull out the 1.0 mm (0.0394 in.) diameter pin from the generator brush holder assembly.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A004A32

      Install the generator terminal insulator to the generator coil assembly.

      Note

      Be sure to install the generator terminal insulator in the correct direction.

  6. INSTALL GENERATOR REAR END COVER


    1. A004A1O

      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 }

  7. INSTALL GENERATOR PULLEY WITH CLUTCH


    1. Secure the generator housing stay in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Temporarily install the generator pulley with clutch to the generator rotor assembly shaft.

    3. A004AJ4E03
      Text in Illustration
      *a Generator Rotor Assembly Shaft

      Place the rotor shaft end into SST1.

      SST
      09820-63021
    4. A0048KEE01
      Text in Illustration
      *1 Generator Pulley with Clutch

      Fit SST2 to the generator pulley with clutch.

      Note

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

    5. A004765E04
      Text in Illustration
      *a Hold
      *b Turn
      *c Fulcrum Length of SST
      *d Fulcrum Length of Torque wrench

      Tighten the generator pulley with clutch by turning SST (B) as shown in the illustration.

      SST
      09820-63021
      Torque:
      Specified tightening torque
      111 N*m  { 1132 kgf*cm, 82 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using SST (Fulcrum length of 100 mm (3.94 in.)) + torque wrench (Fulcrum length of 400 mm (15.75 in.)): 88 N*m (897 kgf*cm, 65 ft. *lbf).

    6. Remove SST from the generator pulley with clutch.

    7. Remove the generator assembly from the vise.

  8. INSTALL GENERATOR PULLEY CAP


    1. A00477O

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