Charging System - Generators & Regulators: Overhaul Toyota MR2 W30

Disassembly

1. Remove nut and terminal insulator. Remove one bolt, 3 nuts, plate terminal and end cover. (Scheme 3) Remove brush holder cover. Remove 5 screws, brush holder and voltage regulator. Remove seal plate from rectifier end frame. Remove 4 screws and rectifier holder. Remove 4 rubber insulators.
2. 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 4) 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.
3. Using Bearing Puller (SST 09286-46011), remove rectifier end frame. Remove generator washer from rotor. Remove rotor from drive end frame.

Scheme 3

Scheme 4

Assembly

To assemble, reverse disassembly procedure. Use generator Pulley Set Nut Wrench Set (SST 09820-63011) to install generator pulley. Place SST "C" securely into a vise. Install SST "A" and "B" and generator into SST "C". (Scheme 4) Tighten pulley nut in opposite direction of disassembly. See TORQUE SPECIFICATIONS. Using 29 mm socket, slowly press in rectifier end frame. To complete assembly, reverse disassembly procedure. After completing assembly, verify rotor turns smoothly.