2AZ-FE Charging: Generator: Reassembly

1. Place the generator drive end frame on the generator pulley.
Fig 1: Identifying Generator Drive End Frame On Generator Pulley
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2. Install the washer onto the generator rectifier end frame.
3. Install the generator rotor onto the generator rectifier end frame.
   Fig 2: Identifying Generator Rotor

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4. Using a 32 mm socket wrench and press, slowly push the generator drive end frame onto the generator rectifier end frame.
   Fig 3: Identifying Generator Drive End Frame

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5. Tighten the 4 bolts.

   Torque: 5.8 N*m (60 kgf*cm, 51 in.*lbf) 

   Fig 4: Identifying Generator Rectifier End Frame Bolts

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6. Install the cord clip with the bolt.

   Torque: 4.56 N*m (45 kgf*cm, 40 in.*lbf) 

   Fig 5: Identifying Cord Clip Bolt

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1. While pushing the 2 brushes into the generator brush holder, insert a 1.0 mm (0.039 in.) pin into the generator brush holder.
   Fig 6: Inserting Pin Into Generator Brush Holder

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2. Install the generator brush holder with the 2 screws.

   Torque: 1.76 N*m (15 kgf*cm, 16 in.*lbf) 

3. Pull the 1.0 mm (0.039 in.) pin out of the generator brush holder.
   Fig 7: Identifying Pulling Pin Out Of Generator Brush Holder

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4. Install the terminal insulator onto the generator rectifier end frame.
   Fig 8: Identifying Terminal Insulator

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5. Install the generator rear end cover with the 3 nuts.

   Torque: 4.6 N*m (45 kgf*cm, 41 in.*lbf) 

   Fig 9: Identifying Generator Rear End Cover With Nuts

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SST 09820-63011 (09820-06010), 09820-06021 

1. Install the generator pulley onto the generator rotor shaft, and then temporarily tighten the generator pulley nut by hand.
   Fig 10: Identifying Generator Pulley Nut

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2. Tighten SST 1-B to the specified torque, and then fix SST 1-A on the generator rotor shaft.
   Fig 11: Tightening SST 1-B

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   SST SPECIFICATION
   
   

   Item	Part No.
   SST 1-A and B	09820-06010
   SST 2	09820-06021

   Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

   NOTE: Securety fix SST on the generator rotor shaft.
3. Clamp SST 2 in a vise.
4. Insert SST 1-A and B into SST 2, and then fix the generator pulley nut into SST 2.
   Fig 12: Inserting SST 1-A And B Into SST 2

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5. Turn SST 1-A in the direction shown, and then loosen the generator pulley nut.

   Torque: 110.3 N*m (1,125 kgf*cm, 82 ft.*lbf) 

   Fig 13: Turning SST 1-A

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6. Remove the generator from SST 2.
7. Fix SST 1-B, then loosen SST 1-A in the direction shown. Remove SST 1-A and B from the generator.
   Fig 14: Identifying SST 1-A And B

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8. Turn the generator pulley, and then check that the generator pulley moves smoothly.