Toyota CH-R Service Manual: Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL GENERATOR DRIVE END FRAME BEARING

(a) Using SST and a press, install a new generator drive end frame bearing.

SST: 09950-60010

09951-00470

SST: 09950-70010

09951-07100

(b) Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.

*a

Tab

*b

Cutout

(c) Install the 4 screws.

Torque:

2.3 N·m {23 kgf·cm, 20 in·lbf}

2. INSTALL GENERATOR ROTOR ASSEMBLY

(a) Place the generator drive end frame on the generator pulley with clutch.

*1

Generator Rotor Assembly

*2

Generator Drive End Frame

(b) Install the generator rotor assembly to the generator drive end frame.

3. INSTALL GENERATOR COIL ASSEMBLY

(a) Install a new bearing cover packing.

NOTICE:

Align the protrusions of the bearing cover packing with the grooves of the generator coil assembly when installing.

*a

Protrusion

*b

Groove

(b) Using SST and a press, slowly press the generator coil assembly to install it.

SST: 09612-70100

09612-07240

(c) Install the 4 bolts.

Torque:

5.9 N·m {60 kgf·cm, 52 in·lbf}

4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

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

*a

Pin (1.0 mm)

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

Torque:

1.8 N·m {18 kgf·cm, 16 in·lbf}

*a

Pin (1.0 mm)

(c) Pull out the pin from the generator brush holder assembly hole.

5. INSTALL GENERATOR TERMINAL INSULATOR

(a) Install the generator terminal insulator to the generator coil assembly.

NOTICE:

Be sure to install the generator terminal insulator in the correct direction.

6. INSTALL GENERATOR REAR END COVER

(a) Install the generator rear end cover to the generator coil assembly with the 3 bolts.

Torque:

4.6 N·m {47 kgf·cm, 41 in·lbf}

7. INSTALL GENERATOR PULLEY WITH CLUTCH

(a) Secure the generator drive end frame in a vise between aluminum plates.

(b) Temporarily install the generator pulley with clutch to the rotor shaft.

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

SST: 09820-63021

(d) Place the rotor shaft end into SST (A).

*a

Rotor Shaft

(e) Fit SST (B) to the generator pulley with clutch.

*1

Generator Pulley with Clutch

(f) Tighten the generator pulley with clutch by turning SST (B) as shown in the illustration.

*a

Hold

*b

Torque Wrench Fulcrum Length

*c

SST Fulcrum Length

Turn

Torque:

Specified tightening torque :

80 N·m {816 kgf·cm, 59 ft·lbf}

NOTICE:

Be careful as the generator pulley with clutch or rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

    Click here

  • When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (15.7 in.)): 64 N*m (653 kgf*cm, 47 ft.*lbf)

(g) Remove SST from the generator pulley with clutch.

(h) Check that the generator pulley with clutch rotates smoothly.

(i) Remove the generator drive end frame from the vise.

8. INSTALL GENERATOR PULLEY CAP

(a) Install a new generator pulley cap to the generator pulley with clutch.

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