Generator (For Bosch Made) Reassembly

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

SST

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

Install the retainer plate with the 4 screws.

Torque:

3.1 N*m{35 kgf*cm, 30 in.*lbf}

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

SST

09285-76010
09630-00014(09631-00061)

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

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

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

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

Install the stator with the 4 bolts.

Torque:

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

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

Install the regulator with the 3 screws.

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

HINT:

Install screw B to the position shown in the illustration.

Install the protective tower.

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

NOTICE:

The protective tower must be attached to the end cover.

Install the 2 terminal covers by turning them clockwise.

Mount the generator in a vise between aluminum plates.

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

SST

09820-30010

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}

Text in Illustration

*1	8 mm Bi-hexagon Wrench
*a	Hold
	Turn

Install a new generator pulley cap.

NOTICE:

1. Align the cap guide of the generator pulley cap with the hole of the generator pulley and push it in by hand.
   
2. Do not push in the generator pulley cap at an angle.