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 on 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 onto the generator 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 RM00000315Z05EX.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 a new generator washer on the generator rotor.

Using SST and a press, press in the generator coil assembly to the drive end frame.

SST

09612-70100(09612-07240)

Install the cord clip with the bolt.

Torque:

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

Tighten the 4 bolts.

Torque:

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

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

Install the generator brush holder with the 2 screws.

Torque:

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

Pull the pin out of the generator brush holder.

Install the terminal insulator onto the generator coil assembly.

NOTICE:

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

Install the generator rear end cover with the 3 nuts.

Torque:

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