GENERATOR (w/ Dual VVT-i) DISASSEMBLY


  1. REMOVE GENERATOR PULLEY CAP


    1. A003CU3

      Using a screwdriver, puncture the center of the generator pulley cap and pry it off.

      Note

      Do not reuse the generator pulley cap.

  2. REMOVE GENERATOR PULLEY WITH CLUTCH


    1. Mount the generator assembly in a vise between aluminum plates.

    2. A003EQ0E01
      Text in Illustration
      *a Generator Rotor Shaft

      Install SST A and SST B to the generator pulley with clutch as shown in the illustration.

      SST
      09820-63021

      Note

      Securely attach SST to the generator pulley with clutch and generator rotor shaft.

    3. A003HKFE01
      Text in Illustration
      *a Hold
      A003DCD Turn

      Using a wrench to hold SST A, turn SST B counterclockwise to loosen the generator pulley with clutch.

      Note

      Be careful as the generator pulley with clutch or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

    4. Remove SST from the generator assembly.

    5. Remove the generator pulley with clutch from the generator rotor shaft.

    6. Remove the generator assembly from a vise.

  3. REMOVE GENERATOR REAR END COVER


    1. A003ENG

      Place the generator assembly on the generator pulley with clutch.

    2. A003DY8

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

  4. REMOVE GENERATOR TERMINAL INSULATOR


    1. A003DGK

      Remove the generator terminal insulator from the generator coil assembly.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A003CCP

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

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. A003FFV

      Remove the 4 bolts.

    2. A003DBCE01
      Text in Illustration
      *a Hold
      A003DCD Turn

      Using SST, remove the generator coil assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )

  7. REMOVE GENERATOR BEARING COVER PACKING


    1. A003ERW

      Remove the generator bearing cover packing.

      Note

      If the generator bearing cover packing breaks, remove all broken pieces.

      Tech Tips

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

  8. REMOVE GENERATOR ROTOR ASSEMBLY


    1. A003AFJ

      Remove the generator rotor assembly.

  9. INSPECT GENERATOR DRIVE END FRAME BEARING


    1. A003D85

      Check that the generator drive end frame bearing is not rough or worn and that it rotates smoothly.

      If necessary, replace the generator drive end frame bearing.

  10. REMOVE GENERATOR DRIVE END FRAME BEARING


    1. A003AER

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

    2. A003AOPE01

      Using SST and a hammer, tap out the generator drive end frame bearing from the generator drive end frame.

      SST
      09950-60010   ( 09951-00250 )
      09950-70010   ( 09951-07100 )