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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
      G01179758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, 3 nuts, plate terminal, end cover and brush holder cover.
      Fig 2: Displaying Plate Terminal
      G01179759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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.
      Fig 3: Removing Brush Holder
      G01179760Courtesy 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
      G01179761Courtesy 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.

      SST 09820-63011

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

    2. Check that SST (A) is secured to the rotor shaft.
      Fig 5: Removing Pulley Using SST
      G01179762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mount SST (C) in a vise.
      Fig 6: Mounting SST In Vise
      G01179763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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).
    7. Turn SST (B), and remove SST (A and B).
      Fig 7: Removing SST A & B
      G01179764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the pulley nut and pulley.
  5. Remove rectifier end frame.
    1. Remove the 4 nuts and wire clip.
      Fig 8: Locating Wire Clip
      G01179765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the rectifier end frame.

      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
    G01179766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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