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Charging Systems: Charging: Disassembly

  1. REMOVE REAR END COVER 
    1. Remove the nut and terminal insulator.
      Fig 1: Removing Nut And Terminal Insulator
      G03146119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, 3 nuts, plate terminal and end cover.
    Fig 2: Removing Plate Terminal And End Cover
    G03146120Courtesy 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 3: Removing Brush Holder Cover From Brush Holder
    G03146121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE RECTIFIER HOLDER 
    1. Remove the 4 screws and rectifier holder.
    2. Remove the 4 rubber insulators.
    Fig 4: Removing Rectifier Holder
    G03146122Courtesy 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 N.m (400 kgf.cm, 29 ft.lbf) 

    2. Check that SST (A) is secured to the rotor shaft.
      Fig 5: Removing Pulley
      G03146123Courtesy 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).
    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: Loosening Pulley Nut
      G03146124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Turn SST (B), and remove SST (A and B).
    8. Remove the pulley nut and pulley.
    Fig 7: Removing Pulley Nut And Pulley
    G03146125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE RECTIFIER END FRAME 
    1. Remove the 4 nuts and wire clip.
      Fig 8: Removing Nuts And Wire Clip
      G03146126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the rectifier end frame.

      SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04041)

    3. Remove the generator washer.
  6. REMOVE ROTOR FROM DRIVE END FRAME 
    Fig 9: Removing Generator Washer
    G03146127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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