Disassembly (90-Amp)
WARNING: This page is about a different car, the 2004 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
- Use generator Pulley Set Nut Wrench Set (SST 09820-63011) to remove generator pulley. Install SST "A" and "B" to rotor shaft and tighten SST "B" clockwise to 29 ft. lbs. (39 N.m). See Fig 1. Place SST "C" securely into a vise. Verify that SST "A" is secured to rotor shaft and install SST "A" and "B" and generator into SST "C". Turn SST "A" in correct direction to loosen pulley nut. To prevent damage to rotor shaft, DO NOT loosen pulley nut more than 1/2 turn. Remove generator from SST "C". Turn SST "A" and "B", remove pulley nut and pulley.
- Remove nut and terminal insulator. Remove bolt, 3 nuts, plated terminal and rear end cover. See Fig 2. Remove 2 screws and brush holder. Remove 3 screws and voltage regulator. Remove 4 screws and diode (rectifier) holder. Remove 4 rubber insulators.
- Remove 4 nuts and wire clip. Using Bearing Puller (SST 09286-46011), remove rectifier end frame. Remove generator washer from rotor. Remove rotor from drive end frame.