Disassembly and Reassembly

Generator (3RZ-FE):

DISASSEMBLY
1. REMOVE REAR END COVER

a. Remove the nut and terminal insulator.

b. Remove the 3 nuts, and end cover.

2. REMOVE BRUSH HOLDER

a. Remove the 2 screws and brush holder.
b. Remove the brush holder cover from the brush holder.

3. REMOVE VOLTAGE REGULATOR

Voltage Regulator (3RZ-FE):

Remove the 3 screws and voltage regulator.

4. REMOVE RECTIFIER HOLDER

a. Remove the 4 screws and rectifier holder.
b. Remove the 4 rubber insulators.

5. REMOVE PULLEY

a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63010

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

b. Check that SST (A) is secured to the rotor shaft.

c. Mount SST (C) in a vise.
d. Install the generator to SST (C).

e. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.

NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.

f. Remove the generator from SST (C).

g. Turn SST (B) and remove SST (A and B).
h. Remove the pulley nut and pulley.

6. REMOVE RECTIFIER END FRAME

a. Remove the 4 nuts.

b. Using SST, remove the rectifier end frame. SST 09286-46011

7. REMOVE ROTOR FROM DRIVE END FRAME

REASSEMBLY

1. PLACE DRIVE END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME

3. INSTALL RECTIFIER END FRAME
a. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
b. Install the 4 nuts.

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

4. INSTALL PULLEY
a. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
b. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63010

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

c. Check that SST (A) is secured to the pulley shaft.

d. Mount SST (C) in a vise.
e. Install the generator to SST (C).

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

Torque: 110 N.m (1,125 kgf.cm, 81 ft.lbf)

g. Remove the generator from SST (C).

h. Turn SST (B), and remove SST (A and B).

5. INSTALL RECTIFIER HOLDER
a. Install the 4 rubber insulators on the lead wires.
b. Install the rectifier holder with the 4 screws.

Torque: 1.96 N.m (20 kgf.cm, 17.4 in.lbf)

6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER

a. Install the brush holder cover to the brush holder.

NOTE: Be careful of the holder installation direction.

(3RZ-FE):

b. Place the voltage regulator together with the brush holder horizontally on the rectifier end frame.

c. Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and connector.
d. Fit the brush holder cover.

7. INSTALL REAR END COVER
a. Install the end cover with the 3 nuts.

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

b. Install the terminal insulator with the nut.

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

8. CHECK THAT ROTOR ROTATES SMOOTHLY