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Charging System (Service Information): Generator: Disassembly: Disassembly

  1. REMOVE GENERATOR REAR END COVER 
    1. Remove the 3 nuts and generator rear end cover.
      Fig 1: Location of Generator Rear End Cover Nuts
      GTY146424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE TERMINAL INSULATOR 
    1. Remove the terminal insulator from the generator coil assembly.
      Fig 2: Location of Terminal Insulator
      GTY146425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Remove the 2 screws and generator brush holder assembly from the generator coil assembly.
      Fig 3: Location of Generator Brush Holder Assembly Screws
      GTY129806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE GENERATOR COIL ASSEMBLY 
    1. Remove the 4 bolts.
      Fig 4: Location of Generator Coil Assembly Bolts
      GTY146426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the generator coil assembly.
      Fig 5: Removing Generator Coil Assembly
      GTY251088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Turn
      *2 Hold
      • SST: 09950-40011 
        • 09951-04020
        • 09952-04010
        • 09953-04020
        • 09954-04010
        • 09955-04071
        • 09957-04010
        • 09958-04011
    3. Remove the generator washer.
      Fig 6: Location of Generator Washer
      GTY127120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE GENERATOR CLUTCH PULLEY 
    1. Using a screwdriver, puncture the center of the generator pulley cap and pry it off.
      Fig 7: Removing Pulley Cap
      GTY291443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not reuse the generator pulley cap.

    2. Mount the generator drive end frame in a vise tightly.
    3. Confirm SST (A) and (B) shown in the illustration.
      Fig 8: Identifying SST
      GTY250882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 SST (A)
      *2 SST (B)
      • SST: 09820-63021 
    4. Place the rotor shaft end into SST (A).
      Fig 9: Placing Rotor Shaft End Into SST
      GTY251169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Rotor Shaft
      *2 SST (A)
    5. Fit SST (B) to the clutch pulley.
      Fig 10: Fitting SST To Clutch Pulley
      GTY250541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Clutch Pulley
      *2 SST (B)
      *3 SST (A)
    6. Loosen the pulley by turning SST (B) in the direction shown in the illustration.
      Fig 11: Loosening Pulley Turning SST
      GTY251229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that the drive end frame is secured in the vise tightly.
      • Hold SST (A) tightly during the operation.
      TEXT IN ILLUSTRATION

      *1 SST (B)
      *2 SST (A)
    7. Remove SST from the generator assembly.
    8. Remove the clutch pulley from the rotor shaft.
  6. REMOVE GENERATOR ROTOR ASSEMBLY 
    1. Remove the generator rotor assembly.
      Fig 12: Location of Generator Rotor Assembly
      GTY145836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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