Section 358 (Charging System - Generators & Regulators): Generator: Disassembly

WARNING: This page is about a different car, the 2002 Toyota Sequoia. 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. See Fig 1.
2. Remove the bolt 3 nuts, plate terminal and end cover.
Remove brush holder :
1. Remove the brush holder cover from the brush holder.
  
  Fig 1: Identifying Nut & Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 screws and brush holder. See Fig 2.
3. Remove the seal plate from the rectifier end frame.
  
  Fig 2: Locating Brush Holder Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove voltage regulator .
Remove the 3 screws and voltage regulator. See Fig 3.

Fig 3: Locating Voltage Regulator Mounting Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove rectifier holder :
1. Remove the nut and cord clip. See Fig 4.
  
  Fig 4: Locating Rectifier Cord Clip Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 screws and rectifier holder. See Fig 5.
3. Remove the 4 rubber insulators.
Fig 5: Locating Rectifier Holder Screws
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. See Fig 6.
  SST 09820-63011
  
  Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
2. Check that SST (A) is secured to the rotor shaft.
  
  Fig 6: Identifying SST A & B
  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). See Fig 7.
  
  Fig 7: Identifying SST A & C
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. See Fig 8.
6. Remove the generator from SST (C).
7. Turn SST (B), and remove SST (A and B).
8. Remove the pulley nut and pulley.
Fig 8: Using SST A & C
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove rectifier end frame .
1. Remove the 3 nuts. See Fig 9.
  
  Fig 9: Locating End Frame Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the rectifier end frame. See Fig 10.
  SST 09286-46011
3. Remove the generator washer from the rectifier end frame.
Fig 10: Removing Rectifier End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove rotor from drive end frame .