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Charging System - Generators & Regulators: Generator: Disassembly

  1. Remove Rear End Cover 
    1. Remove the nut and terminal insulator.
      Fig 1: Removing Nut & Terminal Insulator
      G01101541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the screw, 3 nuts, plate terminal and end cover.
      Fig 2: Removing Generator End Cover
      G01101542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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 3: Removing Brush Holder & Voltage Regulator
      G01101543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Remove Rectifier Holder 
    1. Remove the 4 screws and rectifier holder.
      Fig 4: Removing Rectifier Holder
      G01101544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 rubber insulators.
    3. Remove the seal plate.
  4. Remove Pulley 
    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) 

      Fig 5: Removing Pulley (1 Of 4)
      G01101545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that SST (A) is secured to the rotor shaft.
    3. Mount SST (C) in a vise.
    4. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
      Fig 6: Removing Pulley (2 Of 4)
      G01101546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.
      Fig 7: Removing Pulley (3 Of 4)
      G01101547Courtesy 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 8: Removing Pulley (4 Of 4)
      G01101548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove Rectifier End Frame 
      Fig 9: Removing Rectifier End Frame
      G01101549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the wire clamp.
    2. Remove the 4 nuts and cord clip.
    3. Using SST, remove the rectifier end frame.

      SST 09286-46011

    4. Remove the thrust washer.
  6. Remove Rotor From Drive End Frame 
    Fig 10: Using SST To Remove Rotor From Drive End Frame
    G01101550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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