Charging System - Generators & Regulators: Generator: Reassembly

1. Place the generator washer on the rotor.
   Fig 2: Placing Generator Washer On Rotor

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2. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
   Fig 3: Using Socket To Press In Rectifier End Frame

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3. 80 A:

   Install the cord clip and 4 nuts.

   Fig 4: Installing Cord Clip & Nuts

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   1. Torque: 
      1. A: 4.5 N.m (46 kgf.cm, 40 in.lbf) 
      2. B: 5.4 N.m (55 kgf.cm, 48 in.lbf) 
4. 100 A:

   Install the 4 nuts.

   Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf) 

1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
2. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.

   SST 09820-63011

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

3. Check that SST (A) is secured to the pulley shaft.
   Fig 5: Using SST To Install Pulley To Rotor Shaft

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4. As shown in Fig 6, mount SST (C) in a vise, and install the generator to SST (C).
   Fig 6: Mounting SST (C) In Vise

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5. To torque the pulley nut, turn SST (A) in the direction shown.

   Torque: 110.5 N.m (1,128 kgf.cm, 81 ft.lbf) 

6. Remove the generator from SST (C).
7. Turn SST (B), and remove SST (A and B).

1. Install the 4 rubber insulators on the lead wires.
   Fig 7: Installing 4 Rubber Insulators On Lead Wires.

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2. Install the rectifier holder while pushing it with the 4 screws.

   Torque: 2.94 N.m (30 kgf.cm, 26 in.lbf) 

   Fig 8: Installing Rectifier Holder

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Fig 9: Placing Seal Plate On Rectifier End Frame
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1. Place the seal plate on the rectifier end frame.
2. Place the voltage regulator and brush holder on the rectifier end frame.
   Fig 10: Installing Voltage Regulator & Brush Holder

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   NOTE: Be careful of the holder installation direction.
3. Install the 5 screws.

   Torque: 2.0 N.m (20 kgf.cm, 17 in.lbf) 

4. Place the brush holder cover on the brush holder.
   Fig 11: Placing Brush Holder Cover On Brush Holder

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1. Install the end cover and plate terminal with the 2 nuts and bolt.
   Fig 12: Installing Rear End Cover & Plate Terminal

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   1. Torque: 
   2. Bolt: 3.8 N.m (39 kgf.cm, 34 in.lbf) 
   3. Nut: 4.4 N.m (45 kgf.cm, 39 in.lbf) 
2. Install the rear end cover with the 3 nuts.
   Fig 13: Installing Rear End Cover

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   Torque: 4.4 N.m (45 kgf.cm, 39 in.lbf) 

3. Install the terminal insulator with the nut.
   Fig 14: Installing Terminal Insulator

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   Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf) 

INSTALL GENERATOR COVER (Canada) AND CORD CLIP 

1. Canada:

   Install the cord clip and generator cover with the bolt and nut.

   Torque: 16.6 N.m (170 kgf.cm, 12 ft.lbf) 

2. Except Canada:

   Install the cord clip with the bolt.

   Torque: 16.6 N.m (170 kgf.cm, 12 ft.lbf)