Charging System (2ZR-FE): Generator: Disassembly

REMOVE GENERATOR CLUTCH PULLEY
1. Using a screwdriver, puncture the center of the generator pulley cap and pry it off.
  NOTE: Do not reuse the generator pulley cap.
  
  Fig 1: Puncturing Center Of Generator Pulley Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set SST (A) and (B).
  SST 09820-63021
  
  Fig 2: Setting SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
7. Remove the generator assembly from SST.
8. Remove the clutch pulley from the rotor shaft.
  
  Fig 5: Loosening Pulley By SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR REAR END COVER
1. Place the generator assembly on the clutch pulley.
  
  Fig 6: Identifying Generator Assembly On Clutch Pulley
  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 from the generator coil.
  
  Fig 8: Locating Terminal Insulator From Generator Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
1. Remove the 2 screws and generator brush holder assembly from the generator coil.
  
  Fig 9: Locating Generator Brush Holder Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 10: Locating Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the generator coil assembly.
  SST 09950-40011 (09951-04020,09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011)
  
  Fig 11: Removing Generator Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the generator washer.
  
  Fig 12: Locating Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the generator rotor assembly.
  
  Fig 13: Locating Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and bearing retainer plate from the drive end frame.
  
  Fig 14: Locating Generator Drive End Frame Bearing Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the generator drive end frame bearing from the generator drive end frame.
  SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
  
  Fig 15: Tapping Out Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002