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

REMOVE GENERATOR CLUTCH PULLEY
1. Using a screwdriver, puncture the center of the generator pulley cap and pry it off.
  
  Fig 1: Puncturing Center Of Generator Pulley Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not reuse the generator pulley cap.
2. Set SST (A) and (B).
  
  Fig 2: Setting SST (A) And (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09820-63020
3. Clamp SST (A) in a vise.
4. Place the rotor shaft end into SST (A).
  
  Fig 3: Placing Rotor Shaft End Into SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 4: Fitting SST To Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Loosen the pulley by turning SST (B) in the direction shown in the illustration.
  
  Fig 5: Removing Generator Assembly from the SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the generator assembly from the SST.
8. Remove the clutch pulley from the rotor shaft.
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
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: Locating Generator Rear End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR TERMINAL INSULATOR
1. Remove the terminal insulator.
  
  Fig 8: Locating Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
1. Remove the 2 screws and generator brush holder.
  
  Fig 9: Locating Generator Brush Holder Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 10: Locating Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt and cord clip.
  
  Fig 11: Locating Bolt And Cord Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, remove the coil.
  
  Fig 12: Removing Coil Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-40011
    - 09951-04020
    - 09952-04010
    - 09953-04020
    - 09954-04010
    - 09955-04071
    - 09957-04010
    - 09958-04011
REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the washer.
  
  Fig 13: Locating Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the generator rotor.
  
  Fig 14: Locating Generator Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and bearing retainer.
  
  Fig 15: Locating Screws And Bearing Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the bearing.
  
  Fig 16: Tapping Out Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00250
  - SST: 09950-70010
    - 09951-07100