Generator Reassembly

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

SST

09950-60010(09951-00470)
09950-70010(09951-07100)

Fit the tabs of the bearing retainer plate into the cutouts on the drive end frame to install the bearing retainer plate.

Install the 4 screws.

Torque:

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

Place the drive end frame on the clutch pulley.

Install the generator rotor assembly to the drive end frame.

Temporarily install the clutch pulley onto the rotor shaft.

Mount the generator drive end frame in a vise tightly.

Confirm SST (A) and (B) shown in the illustration.

SST

09820-63021

Place the rotor shaft end into SST (A).

Fit SST (B) to the clutch pulley.

Tighten the pulley by turning SST (B) in the direction shown in the illustration.

Torque:

without SST:

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

with SST:

64 N*m{653 kgf*cm, 47 ft.*lbf}

NOTICE:

1. The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.) and a torque wrench with a fulcrum length of 400 mm (1.312 ft.) (COROLLA_ZRE142 RM000000UYX0ETX.html).
   
2. The "with SST" torque value is effective when SST is parallel to the torque wrench.
   
3. Check that the drive end frame is secured in the vise tightly.
   
4. Hold SST (A) tightly during the operation.
   

Remove SST from the generator assembly.

Check that the clutch pulley rotates smoothly.

Install a new clutch pulley cap to the clutch pulley.

Place the generator washer on the generator rotor.

Using SST and a press, slowly press in the generator coil assembly.

SST

09612-70100(09612-07240)

Install the 4 bolts.

Torque:

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

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

Install the brush holder assembly to the generator coil with the 2 screws.

Torque:

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

Pull out the pin from the generator brush holder.

Install the terminal insulator to the generator coil.

NOTICE:

Make sure to install the terminal insulator in the direction shown in the illustration.

Install the generator rear end cover to the generator coil with the 3 nuts.

Torque:

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