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Charging (Service Information): Generator: Disassembly: Disassembly

  1. REMOVE GENERATOR PULLEY 
    Fig 1: Identifying Generator Pulley
    GTY161806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • SST: 09820-63011 
      • 09820-06010
    • SST: 09820-06021 
    1. Tighten SST 1-B to the specified torque, and then fix SST 1-A on the generator rotor shaft.
      Item Part No.
      SST 1-A and B 09820-06010
      SST 2 09820-06021

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

      NOTE:

      Securely fix SST on the generator rotor shaft.

      2. Fig 2: Inserting SST 1-A And B Into SST 2
      GTY161807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clamp SST 2 in a vise.
    3. Insert SST 1-A and B into SST 2, and then fix the generator pulley nut into SST 2.
      4. Fig 3: Turning SST 1-A
      GTY163137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      If the generator pulley nut is turned by more than a half turn, the generator rotor shaft may be damaged.

    4. Turn SST 1-A in the direction shown, and then loosen the generator pulley nut.
    5. Remove the generator from SST 2.
      6. Fig 4: Removing SST 1-A And B From Generator
      GTY167081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Fix SST 1-B, and then loosen SST 1-A in the direction shown. Remove SST 1-A and B from the generator.
      7. Fig 5: Identifying Generator Pulley Nut
      GTY164120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the generator pulley nut and generator pulley.
  2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    Fig 6: Identifying Nuts And Generator Rear End Cover
    GTY162772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place the generator on the generator pulley.
    2. Remove the 3 nuts and generator rear end cover.
      3. Fig 7: Identifying Terminal Insulator
      GTY161808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the terminal insulator.
      4. Fig 8: Removing Generator Brush Holder
      GTY165537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 screws and generator brush holder.
  3. REMOVE GENERATOR ROTOR ASSEMBLY 
    Fig 9: Identifying Cord Clip Bolt
    GTY162936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt and cord clip.
      2. Fig 10: Removing Generator Assembly Bolts
      GTY161809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts.
      3. Fig 11: Identifying Generator Drive End Frame
      GTY161810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the generator drive end frame.
      • SST: 09950-40011 
        • 09951-04020
        • 09952-04010
        • 09953-04020
        • 09954-04010
        • 09955-04071
        • 09957-04010
      4. Fig 12: Identifying Generator Rotor
      GTY165850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the generator rotor from the generator rectifier end frame.
      5. Fig 13: Installing Washer Onto Generator Rectifier End Frame
      GTY161811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the washer from the generator rectifier end frame.
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