Generators & Regulators: Overhaul Scion xA I

Disassembly

1. Use generator Pulley Set Nut Wrench Set (SST 09820-63010) to remove generator pulley. To remove pulley, install SST "A" and "B" to rotor shaft and tighten SST "B" clockwise to 29 ft. lbs. (39 N.m). (Scheme 3) 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. To prevent damage to rotor shaft, DO NOT loosen pulley nut more than 1/2 turn. Remove generator from SST "C". Turn SST "A" and "B", remove pulley nut and pulley.
2. Remove nut and terminal insulator. Remove 3 nuts, one bolt, plated terminal and end cover. (Scheme 2)
3. Remove brush cover. Remove 2 screws and brush holder. Remove 3 screws and voltage regulator.
4. Remove 4 screws and diode (rectifier) holder.
5. Remove 4 rubber insulators from rectifier end frame. Remove generator seal plate from rotor. Remove 4 nuts and clip code. Using Bearing Puller (SST 09286-46011), remove rectifier end frame.
6. Remove generator washer from rotor. Remove rotor from drive end frame.

Scheme 2

Scheme 3

Assembly

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 "C". (Scheme 3) Tighten pulley nut in the opposite direction of disassembly. See TORQUE SPECIFICATIONS. Using 19 mm socket, slowly press in rectifier end frame. To complete assembly procedure, reverse disassembly procedure. After completing assembly, verify rotor turns smoothly.