Charging Systems: Generator: Disassembly

Remove rear end cover.
1. Remove the 3 nuts and end cover.
2. Remove the terminal insulator.
  
  Fig 1: Removing Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove brush holder.
1. Remove the rear seal plate from the brush holder.
2. Remove the 2 screws and brush holder.
3. Remove the front seal plate from the coil assembly.
  
  Fig 2: Removing Brush 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.
  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 3: Tightening SST To Specific Torque
  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 4: 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).
  
  Fig 5: Loosening Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Turn SST (B), and remove SST (A and B).
8. Remove the pulley nut and pulley.
  
  Fig 6: Removing SST A & B
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove coil assembly.
1. Remove the 4 bolts.
  
  Fig 7: Locating Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the coil assembly.
  SST 09950-40011 (09951-04020, 09952-04010 09953-04020, 09954-04010, 09955-04071, 09958-04011)
3. Remove the generator washer.
Remove rotor from drive end frame.

Fig 8: Removing Coil Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002