Charging System: Generator: Disassembly

REMOVE REAR END COVER 

1. Remove the nut and terminal insulator.
   Fig 1: Removing Nut & Terminal Insulator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt, 3 nuts, plate terminal, end cover and brush holder cover.
   Fig 2: Removing Bolt, 3 Nuts, Plate Terminal, End Cover & Brush Holder Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE REAR END COVER 

Remove the 3 nuts and terminal insulator.

Fig 3: Removing 3 Nuts & Terminal Insulator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 4: Removing 5 Screws, Brush Holder & Voltage Regulator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE BRUSH HOLDER AND TERMINAL INSULATOR 

1. Remove the terminal insulator.
   Fig 5: Removing Terminal Insulator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 screws and brush holder.
   Fig 6: Removing 2 Screws & Brush Holder

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE RECTIFIER HOLDER 

1. Remove the 4 screws and rectifier holder.
2. Remove the 4 rubber insulators.
   Fig 7: Removing 4 Screws & Rectifier Holder

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 8: Installing SST (A & B) To Remove Pulley

   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 9: Inserting SST (B) Into SST (C), & Attaching Pulley Nut To SST (C)

   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 10: Removing Generator From SST (C)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Turn SST (B), and remove SST (A and B).
8. Remove the pulley nut and pulley.
   Fig 11: Removing Pulley Nut & Pulley

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE RECTIFIER END FRAME 

1. Remove the 4 nuts and wire clip.
   Fig 12: Removing 4 Nuts & Wire Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the rectifier end frame.

   SST 09286-46011

3. Remove the generator washer from the rotor.
   Fig 13: Removing Rectifier End Frame (12V 90 A Type)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE RECTIFIER END FRAME 

1. Remove the 4 bolts.
2. Remove the bolt and cord clip.
   Fig 14: Removing 4 Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, remove the rectifier end frame.

   SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071)

4. Remove the alternator washer from the rotor.