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HOMESERVICE MANUALSTOYOTA2005ECHO 2D SEDAN, STANDARDREPAIR AND DIAGNOSIS (SINGLE PAGE)ELECTRICALCHARGING SYSTEMSCHARGING SYSTEMGENERATORDISASSEMBLY

2005 Toyota ECHO 2D Sedan, Standard

Charging System: Generator: Disassembly

2005 Toyota ECHO 2D Sedan, StandardSECTION Disassembly

REMOVE REAR END COVER
1. Remove the nut and terminal insulator.
  
  Fig 1: Removing Nut Of Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt, 3 nuts, plate terminal and end cover.
Fig 2: Removing Plate Terminal And End Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR
1. Remove the brush holder cover from the brush holder.
2. Remove the 5 screws, brush holder and voltage regulator.
3. Remove the seal plate from the rectifier end frame.
Fig 3: Removing Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RECTIFIER HOLDER
1. Remove the 4 screws and rectifier holder.
2. Remove the 4 rubber insulators.
Fig 4: Removing Rubber Insulators
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PULLEY
1. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
  SST 09820-63011
  
  Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
2. Check that SST (A) is secured to the rotor shaft.
  
  Fig 5: Tightening SST Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Mount SST (C) in a vise.
4. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
  
  Fig 6: Inserting SST Into SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.
  NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
6. Remove the generator from SST (C).
  
  Fig 7: Turning SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Turn SST (B), and remove SST (A and B).
8. Remove the pulley nut and pulley.
Fig 8: Removing SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RECTIFIER END FRAME
1. Remove the 4 nuts and wire clip.
  
  Fig 9: Removing Nuts Of Wire Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the rectifier end frame.
  SST 09286-46011
3. Remove the generator washer from the rotor
REMOVE ROTOR FROM DRIVE END FRAME

Fig 10: Removing Rectifier End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002