Charging System (2AR-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 And 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.
4. Remove the generator pulley.
REMOVE GENERATOR REAR END COVER
1. Place the generator on the generator pulley.
  
  Fig 3: Loosening 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 Using SST
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 Bearing Using SST And Press
  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