Section 378 (Charging System - Generators & Regulators): Generator: Disassembly

WARNING: This page is about a different car, the 2002 Toyota Avalon. 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 Nut & Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the screw, 3 nuts, plate terminal and end cover.
  
  Fig 2: Removing Generator End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 3: Removing Brush Holder & Voltage Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove Rectifier Holder
1. Remove the 4 screws and rectifier holder.
  
  Fig 4: Removing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 rubber insulators.
3. Remove the seal plate.
Remove Pulley
1. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
  SST 09820-63011
  
  Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
  
  Fig 5: Removing Pulley (1 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that SST (A) is secured to the rotor shaft.
3. Mount SST (C) in a vise.
4. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
  
  Fig 6: Removing 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.
  
  Fig 7: Removing Pulley (3 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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)
7. Turn SST (B), and remove SST (A and B).
8. Remove the pulley nut and pulley.
  
  Fig 8: Removing Pulley (4 Of 4)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove Rectifier End Frame
1. Remove the wire clamp.
2. Remove the 4 nuts and cord clip.
3. Using SST, remove the rectifier end frame.
  SST 09286-46011
4. Remove the thrust washer.
Remove Rotor From Drive End Frame

Fig 10: Using SST To Remove Rotor From Drive End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002