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

PROCEDURE


  1. INSTALL GENERATOR ROTOR ASSEMBLY

    A01VDQE

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

    2. Using a plastic hammer, install the generator rotor assembly to the generator drive end frame assembly.

    3. A01VLY5

      Install a new generator washer on the generator rotor assembly.

    4. A01VEULE01
      Text in Illustration
      *1 29mm/12pt Socket Wrench

      Using a 29mm/12pt socket wrench and press, slowly press in the generator rectifier end frame.

    5. A01VF02E01
      Text in Illustration
      *1 Terminal Insulator

      Install the 4 nuts.

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

    6. Install the 3 terminal insulators onto the generator rectifier end frame.

  2. INSTALL GENERATOR HOLDER WITH RECTIFIER

    A01VILM

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

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  3. INSTALL GENERATOR REGULATOR ASSEMBLY

    A01VK59

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

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

    A01VKI9E06
    Text in Illustration
    *1 Generator Brush Cover
    *2 Generator Brush Holder Assembly
    *3 Generator Plate Seal

    1. Install the generator plate seal.

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

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

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

  5. INSTALL GENERATOR REAR END COVER


    1. A01VGGEE03
      Text in Illustration
      *1 Rectifier Plate

      Install the generator rear end cover with the 2 nuts B.

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

    2. Install the rectifier plate with the nut A and screw.

      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }
      for nut A
      Torque:
      3.9 N*m  { 40 kgf*cm, 35 in.*lbf }
      for screw

  6. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01VKRC

      Install the generator terminal insulator with the nut.

      Torque:
      4.1 N*m  { 42 kgf*cm, 36 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 tightly.

    3. A01VE5ME02
      Text in Illustration
      *1 Rotor Shaft

      Place the rotor shaft end into SST (A).

      SST
      09820-63021
    4. A01VEQPE08
      Text in Illustration
      *1 Clutch Pulley

      Fit SST (B) to the generator clutch pulley.

    5. A01VIZ9E03
      Text in Illustration
      *a Hold
      *b Turn
      *c Length 100 mm
      *d Length 318 mm

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

      Torque:
      without SST
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
      with SST
      61 N*m  { 622 kgf*cm, 45 ft.*lbf }

      Note


      • Check that the generator drive end frame assembly is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

      Tech Tips


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

      • This torque value is effective when SST 100 mm (5.12 in.) is parallel to the torque wrench.

    6. Remove SST from the generator assembly.

    7. Check that the generator clutch pulley rotates smoothly.

  8. INSTALL GENERATOR PULLEY CAP


    1. Install a new generator pulley cap onto the generator clutch pulley.