GENERATOR(for DENSO Made) REASSEMBLY

Info Added 2017-10-06

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A001SYPN01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A001Y9DC01
      *a Tab
      *b Cutout

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

    2. A001UDI

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

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A001VDQC07
      *a Protrusion
      *b Groove

      Install a new bearing cover packing.

      Note

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

    2. A001SYQC01
      *a 21 mm Deep Socket Wrench

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

    3. Install the 4 bolts.

      Torque:
      5.6 N*m  { 57 kgf*cm, 50 in.*lbf }
  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A001TLXC22
      *a Pin (1.0 mm)

      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. A001WI8C01
      *a Pin (1.0 mm)
      B0049DE Pull out

      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. Pull out the pin from the generator brush holder assembly hole.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. Install the generator terminal insulator to the generator coil assembly.

      Note

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

  6. INSTALL GENERATOR REAR END COVER


    1. 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 assembly 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. A001TMFC03
      *a Rotor Shaft

      Fit the rotor shaft end into SST (A).

      SST
      09820-70010   ( 09821-70010, 09822-70010 )
    4. A001SF6C03
      *1 Generator Pulley with Clutch

      Fit SST (B) to the generator pulley with clutch.

    5. A001UZ0C02
      *a Torque Wrench Fulcrum Length
      *b Turn
      *c Hold

      Using a 17 mm union nut wrench, tighten the generator pulley with clutch by turning SST (B) as shown in the illustration.

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

      Tech Tips


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

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 400 mm (1.312 ft.)): 74.4 N*m (759 kgf*cm, 55 ft.*lbf)

    6. Remove SST (A) and (B) from the generator pulley with clutch.

    7. Check that the generator pulley with clutch rotates smoothly.

    8. Remove the generator assembly from the vise.

  8. INSTALL GENERATOR PULLEY CAP


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