GENERATOR(for DENSO Made) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A004AAME03

      Using SST and a press, install a new generator drive end frame bearing to the generator drive end frame.

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A00484AC03
      *a Tab
      *b Cutout

      Fit the tabs of the retainer plate into the cutouts of the generator drive end frame, and install the retainer plate to the generator drive end frame 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. A0047GR

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

      Note

      Do not drop the generator rotor assembly.

  3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A00477ZC12
      *a Protrusion
      *b Groove

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

      Tech Tips

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

    2. A0048VE

      Temporarily install the generator coil assembly to the generator drive end frame with the 4 through 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 generator coil assembly by tightening the through bolts only.

    3. A004AIFE01

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

      SST
      09612-70100   ( 09612-07240 )

    4. Tighten the 4 through bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A0049F8C04
      *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.) diameter 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. A004BHBC03
      *a 1.0 mm (0.0394 in.) Diameter Pin

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

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A0048JT

      Install the generator terminal insulator to the generator coil assembly.

  6. INSTALL GENERATOR REAR END COVER


    1. A00475O

      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 drive end frame in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

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

    3. A0047TXC07
      *a Rotor Shaft

      Fit the rotor shaft end into SST1.

      SST
      09820-63021
    4. A0046UPC07
      *1 Generator Pulley with Clutch

      Fit SST2 to the generator pulley with clutch.

      Note

      Securely attach SST to the generator pulley with clutch.

    5. A0048T5C04
      *a Hold
      *b Turn
      *c SST Fulcrum Length
      *d Torque Wrench Fulcrum Length

      Using a wrench to hold SST1, turn SST2 clockwise to tighten the generator pulley with clutch.

      Torque:
      Specified tightening torque
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

      Note

      Check that the generator pulley with clutch rotates smoothly and there is no play.

      Tech Tips


      • Assemble the torque wrench and SST2 so that they are in a straight line.

      • 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 (15.7 in.)): 64 N*m (653 kgf*cm, 47 ft.*lbf)

    6. Remove SST1 and SST2 from the generator pulley with clutch.

    7. Remove the generator drive end frame from the vise.

  8. INSTALL GENERATOR PULLEY CAP


    1. A0046T5

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