Toyota CH-R Service Manual: Disassembly

Toyota CH-R Service Manual / 3zr-fae Battery / Charging / Generator / Disassembly

DISASSEMBLY

PROCEDURE

1. REMOVE GENERATOR PULLEY CAP

(a) Using a screwdriver, remove the generator pulley cap from the generator pulley with clutch.

NOTICE:

Do not reuse the generator pulley cap.

2. REMOVE GENERATOR PULLEY WITH CLUTCH

(a) Secure the generator drive end frame in a vise between aluminum plates.

(b) Confirm SST (A) and (B) shown in the illustration.

SST: 09820-63021

(c) Place the rotor shaft end into SST (A).

*a

Rotor Shaft

(d) Fit SST (B) to the generator pulley with clutch.

*1

Generator Pulley with Clutch

(e) Loosen the generator pulley with clutch by turning SST (B) as shown in the illustration.

NOTICE:

  • Check that the generator drive end frame is secured in the vise tightly.
  • Hold SST (A) tightly during the operation.

*a

Turn

*b

Hold

(f) Remove SST from the generator pulley with clutch.

(g) Remove the generator pulley with clutch from the rotor shaft.

(h) Remove the generator assembly from the vise.

3. REMOVE GENERATOR REAR END COVER

(a) Place the generator assembly on the generator pulley with clutch.

(b) Remove the 3 bolts and generator rear end cover from the generator coil assembly.

4. REMOVE GENERATOR TERMINAL INSULATOR

(a) Remove the generator terminal insulator from the generator coil assembly.

5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

(a) Remove the 2 screws and generator brush holder assembly from the generator coil assembly.

6. REMOVE GENERATOR COIL ASSEMBLY

(a) Remove the 4 bolts.

(b) Using SST, remove the generator coil assembly.

SST: 09950-40011

09951-04020

09952-04010

09953-04020

09954-04010

09955-04071

09957-04010

*a

Turn

*b

Hold

(c) Remove the bearing cover packing.

NOTICE:

If the bearing cover packing breaks, remove the broken pieces completely.

HINT:

The bearing cover packing may be installed on the generator rotor assembly.

7. REMOVE GENERATOR ROTOR ASSEMBLY

(a) Remove the generator rotor assembly from the generator drive end frame.

*1

Generator Rotor Assembly

*2

Generator Drive End Frame

8. INSPECT GENERATOR DRIVE END FRAME BEARING

Click here

9. REMOVE GENERATOR DRIVE END FRAME BEARING

(a) Remove the 4 screws and retainer plate from the generator drive end frame.

(b) Using SST and a hammer, tap out the generator drive end frame bearing.

SST: 09950-60010

09951-00250

SST: 09950-70010

09951-07100
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