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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 377 (CHARGING SYSTEM - GENERATORS & REGULATORS - 5VZ-FE)GENERATORDISASSEMBLY
2004 Toyota Matrix XR, FWD, Standard

Section 377 (Charging System - Generators & Regulators - 5VZ-FE): Generator: Disassembly

2004 Toyota Matrix XR, FWD, StandardSECTION Disassembly
WARNING: This page is about a different car, the 2002 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove Rear End Cover 
    1. Remove the nut and terminal insulator.
    2. Remove the bolt 3 nuts, plate terminal and end cover.
    Fig 1: Removing Plate Terminal & End Terminal
    G01092045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove Brush Holder 
    1. Remove the brush holder cover from the brush holder.
    2. Remove the 2 screws and brush holder.
    3. Remove the seal plate from the rectifier end frame.
    Fig 2: Removing Screws & Brush Holder
    G01092046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Remove Voltage Regulator 

    Remove the 3 screws and voltage regulator.

    Fig 3: Removing Voltage Regulator
    G01092047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Remove Rectifier Holder 
    1. Remove the 4 screws and rectifier holder.
    2. Remove the 4 rubber insulators.
    Fig 4: Removing Screws & Rectifier Holder
    G01092048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove Pulley 
    1. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.

      SST 09820-63011

      1. Torque: 
      2. 39 N.m (400 kgf.cm, 29 ft.lbf) 

    2. Check that SST (A) is secured to the rotor shaft.
      Fig 5: Using SST (A) Torque Wrench Tighten SST (B)
      G01092049Courtesy 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 (B) Into SST (C)
      G01092050Courtesy 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).
    7. Turn SST (B), and remove SST (A and B).
    8. Remove the pulley nut and pulley.
    Fig 7: Loosening Pulley Nut
    G01092051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Remove Rectifier End Frame 
    1. Remove the 4 nuts.
      Fig 8: Displaying Rectifier End Frame For Removal
      G01092052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the rectifier end frame.

      SST 09286-46011

    3. Remove the generator washer.
  7. Remove Rotor From Drive End Frame 
    Fig 9: Removing Rectifier End Frame
    G01092053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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