2ZR-FE Charging: Generator: Disassembly

REMOVE GENERATOR CLUTCH PULLEY
1. Using a screwdriver, remove the generator pulley cap.
  
  Fig 1: Removing Generator Pulley Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set SST (A) and (B).
  SST 09820-63020
  
  Fig 2: Identifying SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Clamp SST (A) in a vise.
4. Place the rotor shaft end into SST (A).
  
  Fig 3: Identifying Rotor Shaft End And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) onto the clutch pulley.
  
  Fig 4: Identifying Clutch Pulley With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Loosen the pulley by turning SST (B) in the direction shown in the illustration.
7. Remove the generator assembly from SST.
8. Remove the clutch pulley from the rotor shaft.
REMOVE GENERATOR REAR END COVER
1. Place the generator assembly on the clutch pulley.
  
  Fig 6: Identifying Generator Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 nuts and generator rear end cover.
  
  Fig 7: Identifying Generator Rear End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR TERMINAL INSULATOR
1. Remove the terminal insulator from the generator coil.
  
  Fig 8: Locating Terminal Insulator Of Generator Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
1. Remove the 2 screws and brush holder from the generator coil.
  
  Fig 9: Locating Generator Brush Holder Assembly Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 10: Locating Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the generator coil assembly.
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011, 91111-51014)
  
  Fig 11: Removing Generator Coil Assembly With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the generator washer.
  
  Fig 12: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the generator rotor assembly.
  
  Fig 13: Locating Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and bearing retainer from the drive end frame.
  
  Fig 14: Locating Bearing Retainer Of Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the drive end frame bearing from the drive end frame.
  SST 09950-60010 (09951 -00250), 09950-70010 (09951-07100)
  
  Fig 15: Tapping Drive End Frame Bearing Of Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002