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Section 272 (Charging System - Generators & Regulators): Generator: Disassembly

WARNING: This page is about a different car, the 2002 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE GENERATOR COVER (Canada) AND CORD CLIP 
    1. Canada:

      Remove the bolt, nut, generator cover and cord clip.

    2. Except Canada:

      Remove the bolt and cord clip.

  2. REMOVE REAR END COVER 
    1. Remove the nut and terminal insulator.
      Fig 1: Removing Nut & Terminal Insulator
      G01049111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and rear end cover.
      Fig 2: Removing 3 Nuts & Rear End Cover
      G01049112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts, bolt, plate terminal and rear end cover.
      Fig 3: Removing Rear End Cover
      G01049113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR 
    1. Remove the brush holder cover from the brush holder.
      2. Fig 4: Removing Brush Holder & Voltage Regulator
      G01049114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 screws, brush holder and voltage regulator.
    3. Remove the seal plate from the rectifier end frame.
  4. REMOVE RECTIFIER HOLDER 
    1. Remove the 4 screws and rectifier holder.
      2. Fig 5: Removing Rectifier Holder
      G01049115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 rubber insulators.
  5. 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 6: Removing Pulley With SST
      G01049116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that SST (A) is secured to the rotor shaft.
    3. As shown in Fig 7, mount SST (C) in a vise, and install the generator to SST (C).
      Fig 7: Mounting SST (C) In Vise To Install Generator To SST
      G01049117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. To loosen the pulley nut, turn SST (A) in the direction shown.
      NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
    5. Remove the generator from SST (C).
    6. Turn SST (B), and remove SST (A and B).
    7. Remove the pulley nut and pulley.
  6. REMOVE RECTIFIER END FRAME 
    1. 80 A:

      Remove the 4 nuts and cord clip.

    2. 100 A:

      Remove the 4 nuts.

      Fig 8: Removing Rectifier End Frame
      G01049118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the rectifier end frame.

      SST 09286-46011

      Fig 9: Using SST To Remove Rectifier End Frame
      G01049119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the generator washer.
  7. REMOVE ROTOR FROM DRIVE END FRAME 
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