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

REMOVE GENERATOR REAR END COVER
1. Remove the 3 nuts and generator rear end cover.
  
  Fig 1: 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 2: Locating Terminal Insulator Of 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 3: Locating Generator Brush Holder Assembly Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 4: Locating Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the generator coil assembly.
  
  Fig 5: Removing Generator Coil Assembly Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-40011
    - 09951-04020
    - 09952-04010
    - 09953-04020
    - 09954-04010
    - 09955-04071
    - 09957-04010
    - 09958-04011
3. Remove the generator washer.
  
  Fig 6: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR CLUTCH PULLEY
1. Using a screwdriver, remove the generator pulley cap.
  
  Fig 7: Removing Generator Pulley Cap Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not reuse the generator pulley cap.
2. Mount the generator drive end frame in a vise tightly.
3. Confirm SST (A) and (B) shown in the illustration.
  
  Fig 8: Identifying SST (A) And (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09820-63021
4. Place the rotor shaft end into SST (A).
  
  Fig 9: Placing Rotor Shaft End Into SST (A)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 10: Fitting SST (B) To Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Loosen the pulley by turning SST (B) in the direction shown in the illustration.
  
  Fig 11: Loosening Pulley By Turning SST (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Check that the drive end frame remains secure in the vise.
  - Hold SST (A) tightly during the operation.
7. Remove SST from the generator assembly.
8. Remove the clutch pulley from the rotor shaft.
REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the generator rotor assembly.
  
  Fig 12: Identifying Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR DRIVE END FRAME BEARING See step 4
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and bearing retainer plate from the drive end frame.
  
  Fig 13: Locating Bearing Retainer Of Drive End Frame
  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.
  
  Fig 14: Tapping Drive End Frame Bearing Of Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00250
  - SST: 09950-70010
    - 09951-07100