Generator

Disassembly

1. Remove rear end cover, if equipped. See Fig. 4 . Remove brush holder and IC regulator. Remove diode assembly. Remove rubber insulators or seal plate, if equipped. Use generator Pulley Set Nut Wrench Set (SST 09820-63010) to remove generator pulley.

2. To remove pulley, install SST "A" and "B" to rotor shaft and tighten SST "B" clockwise to 29 ft. lbs. (39 N.m). See Fig. 5 . Place SST "C" securely into a vise. Verify that SST "A" is secured to rotor shaft and install SST "A" and "B" and generator into SST "C". Turn SST "A" in correct direction to loosen pulley nut. See Fig. 5 . To prevent damage to rotor shaft, DO NOT loosen pulley nut more than 1/2 turn. Remove SST "A" and "B" and generator from SST "C". Remove SST "A" and "B" from rotor shaft, and remove pulley nut and pulley.

3. Remove rectifier and frame using appropriate puller. Remove generator washer (if equipped). Remove rotor from drive end frame (stator).

Assembly

To assemble, reverse disassembly procedure. Use generator Pulley Set Nut Wrench Set (SST 09820-63010) to install generator pulley. Place SST "C" securely into a vise. Install SST "A" and "B" and generator into SST

2001 STARTING & CHARGING SYSTEMS Generators & Regulators

"C". See Fig. 5 . Tighten pulley nut to 81 ft. lbs. (110 N.m) in the opposite direction of disassembly. After completing assembly, verify rotor turns smoothly.

Toyota Sst 09820 63010

1.

Pulley

11. Rubber Insulator

2.

Drive End Frame (Stator)

12. Diode Assembly

3.

Front Bearing

13. IC Regulator

4.

Retainer

14. Brush Holder

5.

Rotor

15. Brush

6.

Bearing Cover

16. Spring

7.

Rear Bearing

17. Brush Holder Cover

8.

Bearing Cover

18. Terminal Insulator

9.

Thrust Washer

19. Rear End Cover

10.

Diode End Frame

G97I11203

Fig. 4: Exploded View Of Generator (Celica M/T Shown; All Others Are Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001 STARTING & CHARGING SYSTEMS Generators & Regulators

G93J82155

Fig. 5: Removing Generator Pulley

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001 STARTING & CHARGING SYSTEMS Generators & Regulators

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