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Charging System (2ZZ-GE): Generator: Disassembly

  1. REMOVE GENERATOR PULLEY 

    SST 09820-63010 (09820-06010, 09820-06020) 

    HINT:

    SST 1-A AND B REFERENCE

    SST 1-A and B 09820-06010
    SST 2 09820-06020
    1. Hold SST 1-A with a torque wrench, then tighten SST 1-B counterclockwise to the specified torque.
      Fig 1: Tightening SST 1-B Counterclockwise To Specified Torque
      G04462568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

      NOTE: Securely fix SST on the generator rotor shaft.
    2. Clamp SST 2 in a vise.
    3. Insert SST 1-A and B into SST 2, then attach the pulley nut to SST 2.
      Fig 2: Attaching Pulley Nut To SST 2
      G04462569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. To loosen the pulley nut, turn SST 1-A in the direction shown in the illustration.
      NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than a half turn.
    5. Remove the generator from SST 2.
      Fig 3: Turning SST 1-A
      G04462570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Turn SST 1-B, then remove SST 1-A and B.
    7. Remove the pulley nut, then remove the generator pulley.
  2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Remove the nut, then remove the terminal insulator.
    2. Remove the screw and nut, then remove the terminal plate.
    3. Remove the 2 nuts, then remove the rear end cover.
    4. Remove the generator brush cover from the generator brush holder.
      5. Fig 4: Removing Generator Brush Holder Assembly
      G04462571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 screws, then remove the generator brush holder.
    6. Remove the generator plate seal from the generator rectifier end frame.
  3. REMOVE GENERATOR REGULATOR ASSEMBLY 
    1. Remove the 3 screws, then remove the generator regulator.
  4. REMOVE GENERATOR HOLDER W/RECTIFIER 
    1. Remove the 4 screws, then remove the generator holder with rectifier.
  5. REMOVE GENERATOR RECTIFIER END FRAME 
    1. Remove the 4 terminal insulators from the generator rectifier end frame.
    2. Remove the 4 nuts and generator cord clip.
    3. Using SST, remove the generator rectifier end frame.

      SST 09286-46011 

      Fig 5: Removing Generator Rectifier End Frame
      G04462572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE GENERATOR ROTOR ASSEMBLY 
    1. Remove the generator washer from the generator rotor.
    2. Remove the generator rotor from the generator drive end frame.
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