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Section 121 (Charging): Generator: Disassembly

WARNING: This page is about a different car, the 2002 Lexus GS 430. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove rear end cover.
    1. Remove the nut and terminal insulator.
    2. Remove the bolt, 3 nuts, plate terminal, end cover and brush holder cover.
      Fig 1: Removing Rear End Cover
      G01132887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove brush holder and voltage regulator.
    1. Remove the 5 screws, brush holder and voltage regulator.
      2. Fig 2: Removing Brush Holder & Voltage Regulator
      G01132888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the seal plate from the rectifier end frame.
  3. Remove rectifier holder.
    1. Remove the nut and cord clip.
    2. Remove the 4 screws and rectifier holder.
    3. Remove the 4 rubber insulators.
      Fig 3: Removing Rectifier Holder
      G01132889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Remove pulley.
    1. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
      1. SST 09820-63011
      2. Torque  : 39 N.m (400 kgf.cm, 29 ft.lbf)
    2. Check that SST (A) is secured to the rotor shaft.
      Fig 4: Removing Pulley Using SST
      G01132890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Mount SST (C) in a vise.
    4. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
      Fig 5: Mounting SST In Vise
      G01132891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.
      NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
    6. Remove the generator from SST (C).
    7. Turn SST (B), and remove SST (A and B).
    8. Remove the pulley nut and pulley.
      Fig 6: Loosening Pulley Nut
      G01132892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove rectifier end frame.
    1. Remove the 3 nuts and cord clip.
      Fig 7: Locating Cord Clip & Nuts
      G01132893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Using SST, remove the rectifier end frame.
    1. SST 09286-46011
  7. Remove the generator washer from the rotor.
  8. Remove rotor from drive end frame.
    Fig 8: Removing Rectifier End Frame
    G01132894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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