Charging System: Generator: Disassembly

Remove Rear End Cover
1. Remove the nut and terminal insulator.
2. Remove the screw, 3 nuts, plate terminal and end cover.
  
  Fig 1: Removing Screw, Nuts, Plate Terminal And End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 2: Removing Brush Holder And Voltage Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove Rectifier Holder
1. Remove the 4 screws and rectifier holder.
2. Remove the 4 rubber insulators.
3. Remove the seal plate.
  
  Fig 3: Removing Screws And 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.
  SST 09820-63010
  
  Fig 4: Removing Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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: Mounting SST In Vise
  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: Loosening Pulley Nut With SST
  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).
8. Remove the pulley nut and pulley.
  
  Fig 7: Removing Pulley Nut And Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 09286-4601 1
  
  Fig 9: Removing Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the generator washer.
Remove Rotor From Drive End Frame