Charging System (1AR-FE): Generator: Disassembly

REMOVE GENERATOR PULLEY CAP
1. Using a screwdriver, puncture the center of the generator pulley cap and pry it off.
NOTE: Do not reuse the generator pulley cap.

Fig 1: Removing Generator Pulley Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR PULLEY WITH CLUTCH
1. Mount the generator in a vise.
2. Install SST (A) and (B) to the pulley as shown in the illustration.
  SST 09820-63021
  
  Fig 2: Installing SST (A) And (B) To Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Use a wrench to hold SST (A), and turn SST (B) counterclockwise to loosen the generator pulley.
  NOTE:
  - Check that the drive end frame is secured in the vise tightly.
  - Hold SST (A) tightly during the operation.
4. Remove the generator pulley.
REMOVE GENERATOR REAR END COVER
1. Place the generator on the generator pulley.
  
  Fig 3: Removing Generator Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 nuts and generator rear end cover.
  
  Fig 4: Locating Generator Rear End Cover Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the terminal insulator.
Fig 5: Locating Terminal Insulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
1. Remove the 2 screws and generator brush holder.
Fig 6: Locating Generator Brush Holder Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 7: Locating Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the generator coil.
  SST 09950-40011 (09951 -04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010)
3. Remove the washer.
REMOVE GENERATOR ROTOR ASSEMBLY

Fig 8: Removing Generator Coil
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and bearing retainer.
  
  Fig 9: Locating Bearing Retainer Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the bearing.
  SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
  
  Fig 10: Tapping Out Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press in a new bearing.
  SST 09950-60010 (09951 -00520), 09950-70010 (09951-07100)
  
  Fig 11: Pressing In Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the bearing retainer with the 4 screws.
  Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
  
  Fig 12: Locating Bearing Retainer Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002