Charging Systems: Generator: Disassembly

Remove rear end cover.
1. Remove the nut and terminal insulator.
2. Remove the bolt, 3 nuts, plate terminal, end cover and brush holder cover.
  
  Fig 1: Removing Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove brush holder and voltage regulator.
1. Remove the 5 screws, brush holder and voltage regulator.
2. Remove the seal plate from the rectifier end frame.
Remove rectifier holder.
1. Remove the nut and cord clip.
2. Remove the 4 screws and rectifier holder.
3. Remove the 4 rubber insulators.
  
  Fig 3: Removing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 4: Removing Pulley Using SST
  Courtesy 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).
  
  Fig 5: Mounting SST In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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).
7. Turn SST (B), and remove SST (A and B).
8. Remove the pulley nut and pulley.
  
  Fig 6: Loosening Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove rectifier end frame.
1. Remove the 3 nuts and cord clip.
  
  Fig 7: Locating Cord Clip & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST, remove the rectifier end frame.
1. SST 09286-46011
Remove the generator washer from the rotor.
Remove rotor from drive end frame.

Fig 8: Removing Rectifier End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002