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Charging Systems: Generator: Disassembly

  1. 100 A: REMOVE GENERATOR COVER (CANADA) AND CORD CLIP 
    1. Canada:

      Remove the bolt, nut, generator cover.

    2. Except Canada:

      Remove the bolt and cord clip.

  2. REMOVE REAR END COVER 
    1. Remove the nut and terminal insulator.
      Fig 1: Removing Nut And Terminal Insulator
      G03322201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and rear end cover.
      Fig 2: Removing Nuts And Rear End Cover
      G03322202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts, bolt, plate terminal and rear end cover.
      Fig 3: Removing Nuts, Bolt, Plate Terminal And Rear End Cover
      G03322203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR 
    1. Remove the brush holder cover from the brush holder.
      2. Fig 4: Removing Brush Holder And Voltage Regulator
      G03322204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 screws, brush holder and voltage regulator.
    3. Remove the seal plate from the rectifier end frame.
  4. REMOVE RECTIFIER HOLDER 
    1. Remove the 4 screws and rectifier holder.
      Fig 5: Removing Rectifier Holder
      G03322205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 rubber insulators.
  5. REMOVE PULLEY 
    1. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
      Fig 6: Removing Pulley
      G03322206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09820-63011

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

    2. Check that SST (A) is secured to the rotor shaft.
    3. As shown in Fig 7, mount SST (C) in a vise, and install the generator to SST (C).
      4. Fig 7: Installing Generator To SST
      G03322207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.
      CAUTION: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
    5. Remove the generator from SST (C).
    6. Turn SST (B), and remove SST (A and B).
    7. Remove the pulley nut and pulley.
  6. REMOVE RECTIFIER END FRAME 
    1. 80 A:

      Remove the 4 nuts and cord clip.

      Fig 8: Locating Nuts And Cord Clip For Removal
      G03322208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 100 A:

      Remove the 4 nuts.

    3. Using SST, remove the rectifier end frame.
      Fig 9: Using SST To Remove Rectifier End Frame
      G03322209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09286-46011

    4. Remove the generator washer.
  7. REMOVE ROTOR FROM DRIVE END FRAME 
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