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Charging Systems: Generator: Disassembly

  1. REMOVE REAR END COVER. 
    1. Remove the nut and terminal insulator.
    2. Remove the bolt, 3 nuts, plate terminal and end cover.
      3. Fig 1: Removing Nut & Terminal Insulator
      G03149814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 2: Removing Rear End Cover
      G03149815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR. 
    1. Remove the brush holder cover from the brush holder.
    2. Remove the 5 screws, brush holder and voltage regulator.
    3. Remove the seal plate from the rectifier end frame.
      4. Fig 3: Removing Brush Holder & Voltage Regulator
      G03149816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE RECTIFIER HOLDER. 
    1. Remove the 4 screws and rectifier holder.
    2. Remove the 4 rubber insulators.
      3. Fig 4: Removing Rectifier Holder
      G03149817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE PULLEY. 
    1. Hold SST (SST 09820-63010 A) with a torque wrench, and tighten SST (SST 09820-63010 B) clockwise to the specified torque.
      1. Torque:  39 N.m (400 kgf.cm, 29 ft.lbf)
    2. Check that SST (SST 09820-63010 A) is secured to the rotor shaft.
      Fig 5: Securing SST 09820-63010 A To Rotor Shaft
      G03149818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mount SST (SST 09820-63010 C) in a vise.
    4. Insert SST (SST 09820-63010 B) into SST (SST 09820-63010 C), and attach the pulley nut to SST (SST 09820-63010 C).
    5. To loosen the pulley nut, turn SST (SST 09820-63010 A) in the direction shown. See Fig 6.
      NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
      Fig 6: Mounting SST 09820-63010 C In A Vise
      G03149819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the generator from SST (SST 09820-63010 C).
    7. Turn SST (SST 09820-63010 B), and remove SST (SST 09820-63010 A and SST 09820-63010 B).
    8. Remove the pulley nut and pulley.
      Fig 7: Removing Generator Pulley Nut
      G03149820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE RECTIFIER END FRAME  .
    1. Remove the 4 nuts and wire clip.
      Fig 8: Locating Rectifier End Frame Nuts & Wire Clip
      G03149821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST (SST 09950-40011/09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04041), remove the rectifier end frame.
    3. Remove the generator washer.
      4. Fig 9: Removing Rectifier End Frame
      G03149822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE ROTOR FROM DRIVE END FRAME. 
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