Charging Systems: Generator: Disassembly

REMOVE GENERATOR CLUTCH PULLEY
1. Using a screwdriver, remove the generator pulley cap.
  
  Fig 1: Removing Generator Pulley Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set SST (A) and (B).
  SST 09820-63020
  
  Fig 2: Setting Rotor Shaft To SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Clamp SST (A) in a vise.
  NOTE: Be sure to fix the flat surface of SST (A) in a vise.
  
  Fig 3: Clamping SST (A) In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the rotor shaft end into SST (A).
  
  Fig 4: Placing Rotor Shaft End Into SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 5: 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.
  NOTE: Hold the generator assembly tightly.
7. Remove the generator assembly from SST.
8. Remove the clutch pulley from the rotor shaft.
  
  Fig 6: Loosening Pulley By Turning SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR REAR END COVER
1. Place the generator assembly on the clutch pulley.
  
  Fig 7: Identifying Generator Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 nuts and generator rear end cover.
  
  Fig 8: Locating End Cover Nuts
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REMOVE GENERATOR TERMINAL INSULATOR
1. Remove the terminal insulator from the generator coil.
  
  Fig 9: Locating Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
1. Remove the 2 screws and brush holder from the generator coil.
  
  Fig 10: Locating Generator Brush Holder Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 11: 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 12: Removing Generator Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the generator washer.
  
  Fig 13: Locating Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the generator rotor assembly.
  
  Fig 14: Locating Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002