2009 Toyota Matrix Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Charging System (2ZR-FE): Generator: Reassembly

  1. INSTALL GENERATOR DRIVE END FRAME BEARING 
    1. Using SST and a press, press in a new generator drive end frame bearing.

      SST 09950-60010 (09951-00470), 09950-70010 (09951-07100) 

      Fig 1: Pressing Generator Drive End Frame Bearing
      G06036087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Fit the tabs of the bearing retainer plate into the cutouts on the generator drive end frame to install the bearing retainer plate.
    3. Install the 4 screws.

      Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf) 

  2. INSTALL GENERATOR ROTOR ASSEMBLY 
    1. Place the drive end frame on the clutch pulley.
      Fig 2: Fitting Tabs On Bearing Retainer Plate Into Cutouts
      G05399871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the generator rotor assembly to the generator drive end frame.
      Fig 3: Locating Generator Rotor Assembly
      G06036097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place the generator washer on the generator rotor.
      Fig 4: Identifying Generator Washer
      G06036098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL GENERATOR COIL ASSEMBLY 
    1. Using SST and a press, slowly press in the generator coil assembly to the drive end frame.

      SST 09612-70100 (09612-07240) 

      Fig 5: Pressing Generator Coil Assembly To Drive End Frame
      G05399874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 bolts.

      Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) 

      Fig 6: Locating Generator Coil Assembly Bolts
      G05399857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY 
    1. While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder hole.
      Fig 7: Identifying Pin Into Generator Brush Holder Hole
      G05140123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the brush holder assembly to the generator coil with the 2 screws.

      Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) 

      Fig 8: Locating Generator Brush Holder Assembly Screws
      G05399877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pull out the pin from the generator brush holder assembly.
      Fig 9: Pulling Out Pin From Generator Brush Holder Assembly
      G05399878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL GENERATOR TERMINAL INSULATOR 
    1. Install the terminal insulator to the generator coil.
      NOTE: Be careful to the installation direction of the terminal insulator as shown in the illustration.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.