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Charging System: Generator: Disassembly

  1. REMOVE REAR END COVER 
    1. Remove the nut and terminal insulator.
    2. Remove the bolt, 3 nuts, plate terminal and end cover.
      Fig 1: Removing Plate Terminal
      G02631248Courtesy 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.
    3. Remove the seal plate from the rectifier end frame.
      Fig 2: Identifying Brush Holder Screws
      G02631249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE RECTIFIER HOLDER 
    1. Remove the 4 screws and rectifier holder.
    2. Remove the 4 rubber insulators.
      Fig 3: Identifying Rectifier Holder Screws
      G02631250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE PULLEY 
    1. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.

      SST 09820-63010

      Torque: 39 Nm (400 kgf-cm, 29 ftlbf) 

    2. Check that SST (A) is secured to the rotor shaft.
      Fig 4: Removing Pulley Using SSTs
      G02631251Courtesy 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 5: Inserting SST (B) Into SST (C)
      G02631252Courtesy 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 6: Turning SST (A) To Loosen Pulley Nut
      G02631253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Turn SST (B), and remove SST (A and B).
    8. Remove the pulley nut and pulley.
      Fig 7: Turning SSTs (A And B) For Removal
      G02631254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE RECTIFIER END FRAME 
    1. Remove the 4 nuts and wire clip.
      Fig 8: Identifying Nuts And Wire Clip
      G02631255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the rectifier end frame.

      SST 09286-46011

    3. Remove the generator washer from the rotor.
  6. REMOVE ROTOR FROM DRIVE END FRAME 
    Fig 9: Removing Rectifier End Frame Using SST
    G02631256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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