OEM 2005 Toyota Matrix Alternator

2005 Toyota Matrix Parts Questions & Experts Answers

• Q: How to overhaul the alternator on 2005 Toyota Matrix?

  A: The alternator pulley removal begins with Special Service Tool 09820-63010 (09820-06010, 09820-06020) to attach the holding tool to the rotor shaft while torquing the socket clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf). The alternator adapter needs to be removed after unscrewing the pulley nut by turning it counterclockwise less than a half turn to protect the rotor shaft and continuing by detaching the generator unit and separating the pulley nut and pulley. First remove the generator brush holder assembly by using a nut to eliminate the terminal insulator then the screw, nut, terminal plate and rear end cover then disconnect the generator brush cover and brush holder followed by the generator plate seal. Start by removing three screws from the generator regulator assembly before beginning work on the generator holder with rectifier by removing its four screws. Special Service Tool 09286-46011 requires use to detach the generator rectifier end frame after removing its four terminal insulators and nut configurations. The generator rotor assembly removal starts with removing the washer and rotor from the drive end frame. Measure the generator brush holder assembly for brush length using vernier calipers while checking to see that the standard exposed brush length falls between 9.5 to 11.5 mm (0.374 to 0.453 in.). Replace the brush holder if any brush length measures under 4.5 mm (0.177 in.). Test the resistance of the generator regulator assembly using an ohmmeter and measure the F and B resistance for under 1 Ohm while checking E and F for ten kiloOhms and beyond resistance. Replace the component if it fails this testing process. The generator holder with rectifier requires an inspection of resistance between the positive (+) terminal to each rectifier terminal and between the negative (-) terminal to each rectifier terminal. Testing must be repeated if results deviate from specifications. The generator rotor assembly requires testing of slip rings resistance to rotor alongside checking for bearing damage and roughness along with investigating wear for replacement when needed. The inspection of the generator rectifier end frame should determine its condition for roughness or wear; resistance checks between coil wires and coil wire to body should be performed along with replacement when results fail to meet specifications. To extract the generator rotor bearing on 1ZZ-FE engine vehicles, clamp the rotor onto a vise while using Special Service Tool 09820-00021 to uninstall the bearing cover and bearing. When installing the new bearing proceed by setting the rotor on the pulley then placing the bearing covers before using Special Service Tool 09820-00031 and a press to push in the bearing followed by pushing the outer cover using Special Service Tool 09285-76010. Special Service Tools 09950-60010 (09951-00350) and 09950-70010 (09951-07100) should be used to push out the generator drive end frame bearing. Install a new bearing with the same tools after which the retainer plate requires a torque of 3.0 N.m (31 kgf.cm, 27 in.lbf). The generator drives end frame needs to be installed first followed by the rotor and washer until the generator rectifier end frame reaches its final position using a socket wrench and press. The installation concludes with attaching the generator cord clip and nuts according to specified torques. The installation requires first attaching the rectifier by screwing four nuts to 2.9 N.m (30 kgf.cm, 26 in.lbf) followed by screwing three nuts to the generator regulator assembly at 2.0 N.m (20 kgf.cm, 18 in.lbf). Finally, secure the generator brush holder assembly with the complete set of components while ensuring proper nut torques. Finish by installing the pulley through the use of Special Service Tool 09820-63010 (09820-06010, 09820-06020). Secure the pulley nut manually before setting it into the pulley holding tool and torque it to 111 Nm (1,125 kgf.cm, 81 ft.lbf) while conducting a smooth pulley movement test.