GENERATOR (for DENSO Made) REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY


    1. A01DWL2

      Place the drive end frame on the pulley.

    2. Install the rotor to the drive end frame.

  2. INSTALL GENERATOR COIL ASSEMBLY


    1. A01DXEJ

      Place the generator washer on the rotor.

    2. A01E00SE01

      Using SST and a press, slowly press on the coil assembly.

      SST
      09285-76010
    3. A01E011

      Install the 4 bolts.

      Torque:
      5.8 N*m  { 59 kgf*cm, 51 in.*lbf }

  3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01DVWFE06

      While pushing the 2 brushes inside the brush holder, insert a pin (diameter: 1.0 mm (0.039 in.)) into the brush holder hole.

    2. A01E1ICE01

      Install the generator brush holder 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.

  4. INSTALL GENERATOR REAR END COVER


    1. A01DWI0

      Install the terminal insulator to the generator coil.

      Note

      Pay attention to the mounting orientation of the terminal insulator.

    2. A01DX1G

      Install the end cover with the 3 nuts.

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

  5. INSTALL GENERATOR PULLEY WITH CLUTCH


    1. Mount the generator in a vise between aluminum plates.

    2. Temporarily install the generator pulley by hand.

    3. A01DZGAE01

      Install SST (A) and (B) to the generator pulley as shown in the illustration.

      SST
      09820-63021
    4. A01DW07E01

      Using a wrench to hold SST (A), turn SST (B) clockwise to tighten the generator pulley.

      Torque:
      without SST
      111 N*m  { 1127 kgf*cm, 81 ft.*lbf }
      with SST
      80 N*m  { 814 kgf*cm, 58 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 260 mm (10.2 in.). When using a torque wrench with a fulcrum length that is not 260 mm (10.2 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure SST and the wrench are connected in a straight line.

    5. Check that the generator pulley rotates smoothly.

  6. INSTALL GENERATOR PULLEY CAP


    1. A01DWNAE01

      Install a new generator pulley cap.

      Note


      • Align the cap guide of the generator pulley cap with the hole of the generator pulley and push it in by hand.

      • Do not push in the generator pulley cap at an angle.