Charging System (Service Information): Generator: Disassembly: Disassembly

REMOVE GENERATOR PULLEY CAP
1. Using a screwdriver, remove the generator pulley cap.
  
  Fig 1: Removing Generator Pulley Cap With Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE GENERATOR CLUTCH PULLEY

Mount the generator in a vise between aluminum plates.
Install SST (A) and (B) to the generator with clutch pulley as shown in the illustration.

Fig 2: View of Generator Clutch Pulley Using SST (A & B)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09820-63021
TEXT IN ILLUSTRATION

*1 Rotor Shaft

NOTE:
Securely attach SST to the generator with clutch pulley and generator rotor shaft.

Use a wrench to hold SST (A) and turn SST (B) counterclockwise to loosen the generator with clutch pulley.

NOTE:

Be careful as the generator with clutch pulley or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

Fig 3: Removing Generator Clutch Pulley Using SST (A & B)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Hold
	Turn

Remove SST from the generator.
Remove the generator with clutch pulley from the rotor shaft.

REMOVE GENERATOR REAR END COVER
1. Remove the nut and cord clamp.
  
  Fig 4: Locating Nut And Cord Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 nuts and generator rear end cover.
  
  Fig 5: Identifying Nuts And Generator Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR TERMINAL INSULATOR
1. Remove the terminal insulator from the generator coil.
  
  Fig 6: Identifying Generator Coil & 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 7: Identifying Generator Coil, Brush Holder & Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE GENERATOR COIL ASSEMBLY

Remove the 4 bolts.

Fig 8: Identifying Generator Coil Assembly & Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST, remove the generator coil.

Fig 9: Removing Generator Coil Using SST

SST: 09950-40011
1. 09951-04020
2. 09952-04010
3. 09953-04020
4. 09954-04010
5. 09955-04071
6. 09957-04010
7. 09958-04011

TEXT IN ILLUSTRATION

*a	Hold
	Turn

REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the generator washer.
  
  Fig 10: Locating Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the generator rotor assembly.
  
  Fig 11: Identifying Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and retainer plate from the drive end frame.
  
  Fig 12: Identifying Generator Drive End Frame Bearing, Retainer Plate & Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the drive end frame bearing from the drive end frame.
  
  Fig 13: Tapping Out Drive End Frame Bearing From Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    1. 09951-00250
  - SST: 09950-70010
    1. 09951-07100