Generator (For Denso Made) Reassembly

Using SST and a press, press in a new bearing.

SST

09950-60010(09951-00520)
09950-70010(09951-07100)

Align the claws of the bearing retainer with the grooves inside the generator drive end frame.

Install the bearing retainer with the 4 screws.

Torque:

2.3 N*m{23 kgf*cm, 20 in.*lbf}

Install the rotor and washer to the drive end frame.

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

Install the generator coil with the 4 through bolts.

Torque:

5.9 N*m{60 kgf*cm, 52 in.*lbf}

While pushing the 2 brushes into the generator brush holder, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the brush holder hole.

Install the brush holder with the 2 screws.

Torque:

1.8 N*m{18 kgf*cm, 16 in.*lbf}

Pull out the pin from the brush holder.

Install the generator rear end cover with the 3 nuts.

Torque:

4.6 N*m{46 kgf*cm, 40 in.*lbf}

Install the pulley by hand.

Mount generator in a vise between aluminum plates.

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

SST

09820-63021

NOTICE:

Securely attach SST to the generator with clutch pulley and generator rotor shaft.

Use a wrench to hold SST (A) and turn SST (B) clockwise to tighten the generator with clutch pulley.

Torque:

without SST:

111 N*m{1127 kgf*cm, 81 ft.*lbf}

with SST:

83 N*m{844 kgf*cm, 61 ft.*lbf}

Text in Illustration

*1	Fulcrum Length
*a	Hold
	Turn

NOTICE:

Be careful as the generator with clutch pulley or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

HINT:

1. Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification (HILUX_TGN26 RM000004QR1003X.html).
   
2. Make sure SST and the wrench are connected in a straight line.
   

Remove SST from the generator.

Check that the generator pulley rotates smoothly.

Install a new generator pulley cap.