Section 81 (Charging System (1AR-FE) (Service Information)): Generator: Disassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

REMOVE GENERATOR PULLEY CAP
1. Using a screwdriver, puncture the center of the generator pulley cap and pry it off.
  
  Fig 1: Removing Generator Pulley Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not reuse the generator pulley cap.
REMOVE GENERATOR PULLEY WITH CLUTCH
1. Mount the generator in a vise.
  
  Fig 2: Removing Generator Pulley With Clutch Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install SST (A) and (B) to the pulley as shown in the illustration.
  - SST: 09820-63021
3. Use a wrench to hold SST (A), and turn SST (B) counterclockwise to loosen the generator pulley.
  
  Fig 3: Loosening Generator Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
2. Remove the 3 nuts and generator rear end cover.
  
  Fig 4: Identifying Generator Rear End Cover And Fasteners
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the terminal insulator.
  
  Fig 5: Identifying Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
1. Remove the 2 screws and generator brush holder.
  
  Fig 6: Identifying Generator Brush Holder And Fasteners
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 7: Identifying Generator Coil Assembly And Fasteners
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the generator coil.
  
  Fig 8: Removing Generator Coil Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-40011
    - 09951-04020
    - 09952-04010
    - 09953-04020
    - 09954-04010
    - 09955-04071
    - 09957-04010
3. Remove the washer.
REMOVE GENERATOR ROTOR ASSEMBLY
REPLACE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and bearing retainer.
  
  Fig 9: Identifying Bearing Retainer Fasteners
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the bearing.
  
  Fig 10: Tapping Out Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00250
  - SST: 09950-70010
    - 09951-07100
3. Using SST and a press, press in a new bearing.
  
  Fig 11: Installing Bearing Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00520
  - SST: 09950-70010
    - 09951-07100
4. Install the bearing retainer with the 4 screws.
  
  Fig 12: Identifying Bearing Retainer Fasteners
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)