Disassembly

1ZZ-FE CHARGING: GENERATOR:

COMPONENTS









DISASSEMBLY

1. REMOVE GENERATOR PULLEY
SST: 09820-63010
09820-06010
09820-06020









(a) Hold SST 1-A with a torque wrench, then tighten SST 1-B counterclockwise to the specified torque.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)

NOTE: Securely fix SST on the generator rotor shaft.





(b) Clamp SST 2 in a vise.
(c) Insert SST 1-A and B into SST 2, then attach the pulley nut to SST 2.





(d) To loosen the pulley nut, turn SST 1-A in the direction shown in the illustration.

NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than a half turn.

(e) Remove the generator from SST 2.





(f) Turn SST 1-B, then remove SST 1-A and B.
(g) Remove the pulley nut, then remove the generator pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
(a) Remove the nut, then remove the terminal insulator.
(b) Remove the screw and nut, then remove the terminal plate.
(c) Remove the 2 nuts, then remove the rear end cover.
(d) Remove the generator brush cover from the generator brush holder.
(e) Remove the 2 screws, then remove the generator brush holder.
(f) Remove the generator plate seal from the generator rectifier end frame.
3. REMOVE GENERATOR REGULATOR ASSEMBLY
(a) Remove the 3 screws, then remove the generator regulator.
4. REMOVE GENERATOR HOLDER W/RECTIFIER
(a) Remove the 4 screws, then remove the generator holder with rectifier.
5. REMOVE GENERATOR RECTIFIER END FRAME





(a) Remove the 4 terminal insulators from the generator rectifier end frame.
(b) Remove the 4 nuts and generator cord clip.
(c) Using SST, remove the generator rectifier end frame.
SST: 09286-46011
6. REMOVE GENERATOR ROTOR ASSEMBLY
(a) Remove the generator washer from the generator rotor.
(b) Remove the generator rotor from the generator drive end frame.