Section 360 (Charging System - Generators & Regulators): Generator: Disassembly

WARNING: This page is about a different car, the 2002 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE REAR END COVER
1. Remove the nut and terminal insulator.
  
  Fig 1: Removing Rear End Cover (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt, 3 nuts, plate terminal, end cover and brush holder cover.
  
  Fig 2: Removing Rear End Cover (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR
1. Remove the 5 screws, brush holder and voltage regulator.
2. Remove the seal plate from the rectifier end frame.
  
  Fig 3: Removing Brush Holder & Voltage Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RECTIFIER HOLDER
1. Remove the 4 screws and rectifier holder.
2. Remove the 4 rubber insulators.
  
  Fig 4: Removing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PULLEY
1. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
  1. SST 09820-63011
  2. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
2. Check that SST (A) is secured to the rotor shaft.
  
  Fig 5: Using SSTs To Remove Generator Pulley (1 Of 4)
  Courtesy 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 6: Using SSTs To Remove Generator Pulley (2 Of 4)
  Courtesy 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 7: Using SSTs To Remove Generator Pulley (3 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Turn SST (B), and remove SST (A and B).
8. Remove the pulley nut and pulley.
  
  Fig 8: Using SSTs To Remove Generator Pulley (4 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RECTIFIER END FRAME
1. Remove the 4 nuts and wire clip.
  
  Fig 9: Removing Rectifier End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the rectifier end frame.
  1. SST 09286-46011
3. Remove the generator washer from the rotor
REMOVE ROTOR FROM DRIVE END FRAME

Fig 10: Removing Rotor From Drive End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002