GENERATOR (for BOSCH Made) REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY

    Note

    Do not drop the generator rotor assembly.


    1. A01E22WE01

      Set the spacer ring, drive end frame, generator rotor assembly and SST1 to SST2 as shown in the illustration.

      SST
      09285-76010
      09630-00014   ( 09631-00061 )

    2. Using SST1, SST2 and a press, slowly press the generator rotor into the drive end frame and spacer ring.

    3. Temporarily install the generator pulley with clutch to the rotor shaft by hand.

  2. INSTALL FITTING RING


    1. A01DVVQ

      Align the 3 protrustions of the fitting ring with the 3 cutouts of the generator stator with rectifier and install the fitting ring.

  3. INSTALL GENERATOR STATOR SUB-ASSEMBLY WITH RECTIFIER


    1. Align the key of the drive end frame with the keyway of the generator stator.

    2. A01DVYT

      Install the stator with the 4 bolts.

      Torque:
      4.3 N*m  { 44 kgf*cm, 38 in.*lbf }

  4. INSTALL GENERATOR REGULATOR ASSEMBLY


    1. A01DZNT

      Push in the regulator by hand as shown in the illustration.

    2. Install the regulator with the 3 screws.

      A01E0ETE01
      Torque:
      2.5 N*m  { 25 kgf*cm, 22 in.*lbf, for screw A }
      1.2 N*m  { 12 kgf*cm, 11 in.*lbf, for screw B }

      Tech Tips

      Install screw B to the position shown in the illustration.

    3. Install the protective tower.

  5. INSTALL GENERATOR REAR END COVER


    1. A01DXQ5E01

      Install the rear end cover with the 2 nuts and screw.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf, for nut A }
      12 N*m  { 122 kgf*cm, 9 ft.*lbf, for nut B }
      2.8 N*m  { 29 kgf*cm, 25 in.*lbf, for screw }

      Note

      The protective tower must be attached to the end cover.

    2. A01E2Z5

      Install the 2 terminal covers by turning them clockwise.

  6. TIGHTEN GENERATOR PULLEY WITH CLUTCH


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

    2. A01DVUXE01

      Set SST and an 8 mm bi-hexagon wrench to the pulley as shown in the illustration.

      SST
      09820-30010
    3. A01E1T2E01

      Hold SST in place, rotate the 8 mm bi-hexagon wrench counterclockwise, and tighten the generator pulley with clutch.

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

  7. INSTALL GENERATOR PULLEY CAP


    1. A01DX6IE01

      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.