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Charging Systems: Generator: Disassembly

  1. Remove rear end cover.
    1. Remove the nut and terminal insulator.
      Fig 1: Locating Nut & Terminal Insulator
      G01132187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, 3 nuts, plate terminal and end cover.
      Fig 2: Locating Plate Terminal
      G01132188Courtesy 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.
      Fig 3: Removing Brush Holder & Voltage Regulator
      G01132189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Remove rectifier holder.
    1. Remove the 4 screws and rectifier holder.
    2. Remove the 4 rubber insulators.
      Fig 4: Removing Rectifier Holder
      G01132190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Remove pulley.
    1. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
      1. SST 09820-63011
      2. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
    2. Check that SST (A) is secured to the rotor shaft.
      Fig 5: Tightening SST To Specified Torque
      G01132191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mount SST (C) in a vise.
    4. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
    5. 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.
    6. Remove the generator from SST (C).
      Fig 6: Mounting SST In Vise
      G01132192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Turn SST (B), and remove SST (A and B).
    8. Remove the pulley nut and pulley.
      Fig 7: Removing SST A & B
      G01132193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove rectifier end frame.
    1. Remove the 4 nuts and wire clip.
      Fig 8: Locating Wire Clip
      G01132194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the rectifier end frame.
      1. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04041)
    3. Remove the generator washer.
  6. Remove rotor from drive end frame
    Fig 9: Removing Rectifier End Frame
    G01132195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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