Charging Systems: Generator: Disassembly

REMOVE REAR END COVER
1. Remove the nut and terminal insulator.
2. Remove the screw, 3 nuts, plate terminal and end cover.
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.
REMOVE RECTIFIER HOLDER
1. Remove the 4 screws and rectifier holder.
2. Remove the 4 rubber insulators.
3. Remove the seal plate.
REMOVE PULLEY
1. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
  1. SST 09820-63010
  2. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
2. Check that SST (A) is secured to the rotor shaft.
3. Mount SST (C) in a vise.
  
  Fig 5: Using SSTs To Remove Generator Pulley (2 Of 4)
  Courtesy 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.
  
  Fig 6: Using SSTs To Remove Generator Pulley (3 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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: Using SSTs To Remove Generator Pulley ( 4 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the pulley nut and pulley.
REMOVE RECTIFIER END FRAME
1. Remove the 4 nuts and cord clip.
  
  Fig 8: Removing Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the rectifier end frame. SST 09286-46011
  
  Fig 9: Using SST To Remove Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the generator washer.
REMOVE ROTOR FROM DRIVE END FRAME