Generators & Regulators — Suzuki Grand Vitara I (1997-2001)

DESCRIPTION & OPERATION

Belt-driven generator consists of front and rear housings, sealed bearings, brushes, rectifier, Integrated Circuit (IC) voltage regulator, stator and rotor. The IC voltage regulator is located inside the generator, and voltage regulator output voltage cannot be adjusted. A condenser is located in rear housing, and is used for suppressing radio noise. A charge indicator light on instrument panel comes on to indicate if a charging system malfunction exists.

BELT TENSION

Application			(1) Belt Deflection - In. (mm)
Esteem
A/C			.31-.39 (8.0-10.0)
Generator/Water Pump
New			.20-.27 (5.0-7.0)
Used			.24-.31 (6.0-8.0)
P/S Pump			.31-.39 (8.0-10.0)
Grand Vitara & Vitara (2.5L)
Generator/Water Pump
New			.27-.35 (7.0-9.0)
Used			.35-.43 (9.0-11.0)
P/S Pump (With Or Without A/C)			.16-.35 (4.0-9.0)
Vitara (1.6L)
Generator/Water Pump
New			.20-.27 (5.0-7.0)
Used			.24-.32 (6.0-8.0)
P/S Pump (With Or Without A/C)			.24-.35 (6.0-9.0)
Vitara (2.0L)
Cooling Fan
New			.16-.19 (4.0-5.0)
Used			.20-.27 (5.0-7.0)
Generator			(2)
Swift
P/S Pump (With Or Without A/C)			.28-.35 (7.0-9.0)
Generator/Water Pump
New			.20-.27 (5.0-7.0)
Used			.24-.31 (6.0-8.0)
(1) Belt deflection is measured with 22 lbs. (10 kg) pressure applied on belt at mid position on longest belt area between pulleys. (2) Automatic belt tensioner is used. No belt tension adjustment is required.

(1)	Belt deflection is measured with 22 lbs. (10 kg) pressure applied on belt at mid position on longest belt area between pulleys.

(2)	Automatic belt tensioner is used. No belt tension adjustment is required.

BELT TENSION SPECIFICATIONS

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.

Esteem, Grand Vitara & Vitara

Check generator wiring harness electrical connections at generator. Check drive belt tension. See «BELT TENSION»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__belt-tension) under ADJUSTMENTS. Ensure battery is fully charged.
Connect voltmeter between ground and generator "B" (battery) terminal. Connect ammeter positive lead to generator "B" (battery) terminal. Connect ammeter negative lead to positive battery terminal on the battery. (Scheme 1)
To check generator no-load output, ensure all accessories are off. Start and idle engine. Increase engine speed to 2000 RPM, and note output voltage and output amperage. Output voltage and output amperage should be within specification. See «GENERATOR OUTPUT SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators) table. NOTE: Output voltage may vary slightly depending on temperature of IC voltage regulator case.
If output voltage and output amperage are within specification, go to step 7. If output voltage is less than specification, go to next step. If output voltage exceeds specification, check ground on brushes. If ground on brushes is okay, replace IC voltage regulator. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__overhaul).
Shut engine off. Ground generator "F" terminal. (Scheme 2) Start engine and increase engine speed to 2000 RPM. Note output voltage. Output voltage should be within specification. See «GENERATOR OUTPUT SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators) table.
If output voltage now exceeds specification, replace IC voltage regulator. If output voltage is still less than specified, generator is defective. Repair or replace generator as necessary. If repairing generator, see «BENCH TESTING»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators).
To check generator high-load output, allow engine to idle. Increase engine speed to 2000 RPM. Turn on headlights and heater motor. Note output amperage. Output amperage should be within specification. See «GENERATOR OUTPUT SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators) table. If output amperage is less than specification, go to next step.
Repair or replace generator as necessary. If repairing generator, see «BENCH TESTING»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators).

Scheme 1

Scheme 2

Swift

Check generator wiring harness electrical connections at generator. Check drive belt tension. See «BELT TENSION»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__belt-tension) under ADJUSTMENTS. Ensure battery is fully charged.
Connect voltmeter between ground and generator "B" (battery) terminal. Connect ammeter positive lead to generator "B" (battery) terminal. Connect ammeter negative lead to positive battery terminal on the battery. (Scheme 1)
To check generator no-load output, ensure all accessories are off. Start and idle engine. Increase engine speed to 2000 RPM and note output voltage and output amperage. Output voltage and output amperage should be within specification. See «GENERATOR OUTPUT SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators) table. NOTE: Output voltage may vary slightly depending on temperature of IC voltage regulator case.
If output voltage and output amperage are within specification, go to next step. If output voltage is less than specified, go to step 6. If output voltage exceeds specification, check ground on brushes. If ground on brushes is okay, replace IC voltage regulator. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__overhaul).
To check generator high-load output, allow engine to idle. Increase engine speed to 2000 RPM. Turn on headlights and heater motor. Note output amperage. Output amperage should be at least 20 amps. If output amperage is less than 20 amps, go to next step.
Repair or replace generator as necessary. If repairing generator, see «BENCH TESTING»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators).

Application			Specification
Esteem & Swift
Output Amperage
At No-Load			10 Amps Maximum
At High-Load			20 Amps Minimum
Output Voltage (1)			14.4-15.0 Volts
Grand Vitara & Vitara (85-Amp Generator)
Output Amperage
At No-Load			10 Amps Maximum
At High-Load			30 Amps Minimum
Output Voltage (1)			14.1-15.2 Volts
Vitara (60- & 70-Amp Generator)
Output Amperage
At No-Load			10 Amps Maximum
At High-Load			(2)
Output Voltage (1)			14.4-15.0 Volts
(1) Output voltage specification listed is at 68°F (20°C). Output voltage may vary slightly depending on temperature of IC voltage regulator case. (2) On 60-amp generator, minimum output specification is 42 amps. On 70-amp generator, minimum output specification is 49 amps.

(1)	Output voltage specification listed is at 68°F (20°C). Output voltage may vary slightly depending on temperature of IC voltage regulator case.

(2)	On 60-amp generator, minimum output specification is 42 amps. On 70-amp generator, minimum output specification is 49 amps.

GENERATOR OUTPUT SPECIFICATIONS

BRUSHES

Inspect brushes for cracks. Ensure brushes slide smoothly in brush holder. With brushes installed in brush holder, measure brush length from end of brush to the inner edge of the brush holder. (Scheme 3) See BRUSH LENGTH SPECIFICATIONS table. Replace brush if brush length is not within specification. See OVERHAUL.

Note. When replacing brushes, it may be necessary to replace brushes and brush holder as an assembly. Consult parts department for available service components.

Application		In. (mm)
Esteem
Standard Brush Length		.413 (10.50)
Wear Limit		.331 (8.40)
Grand Vitara & Vitara (85-Amp Generator)
Standard Brush Length		.413 (10.50)
Wear Limit		.351 (8.92)
Vitara (Except 85-Amp Generator)
Standard Brush Length		.63 (16.0)
Wear Limit		.08 (2.0)
Swift
Standard Brush Length		.63 (16.0)
Wear Limit		.08 (2.0)

BRUSH LENGTH SPECIFICATIONS

Scheme 3

Esteem, Grand Vitara & Vitara (85-Amp Generator)

Testing information is not available from manufacturer.

Swift & Vitara (Except 85-Amp Generator)

Using capacitor tester, check capacity of condenser, located on rectifier. (Scheme 4) Replace rectifier if condenser capacity is not.5 microfarads.

Scheme 4

Scheme 4: Swift & Vitara (Except 85-Amp Generator)

To check positive rectifier, connect ohmmeter leads between "B" terminal and each rectifier terminal. (Scheme 5) Note continuity reading.
Reverse ohmmeter leads and note continuity reading. Continuity should exist with ohmmeter leads in one direction, and no continuity should exist when ohmmeter leads are reversed. Replace rectifier if continuity is not as specified. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__overhaul).
To check negative rectifier, connect ohmmeter leads between each negative terminal and each rectifier terminal. (Scheme 5) Note continuity reading.
Reverse ohmmeter leads and note continuity reading. Continuity should exist with ohmmeter leads in one direction, and no continuity should exist when ohmmeter leads are reversed. Replace rectifier if continuity is not as specified. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__overhaul).

Scheme 5

Connect ohmmeter leads between upper and lower rectifier bodies and each diode lead. Note continuity reading. Perform STEP 1. (Scheme 6)
Reverse ohmmeter leads and note continuity reading. Continuity should exist with ohmmeter leads in one direction, and no continuity should exist when ohmmeter leads are reversed. Replace rectifier if continuity is not as specified. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__overhaul).
Connect ohmmeter leads between both ends of diode trio on rectifier and note continuity reading. Perform STEP 2. (Scheme 6)
Reverse ohmmeter leads and note continuity reading. Continuity should exist with ohmmeter leads in one direction, and no continuity should exist when ohmmeter leads are reversed. Replace rectifier if continuity is not as specified. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__overhaul).

Scheme 6

ROTOR

To test rotor for an open circuit, use ohmmeter to check for continuity between slip rings on end of rotor. (Scheme 7)
Continuity should exist and resistance should be within specification. See «ROTOR SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators) table. Replace rotor if no continuity exists or resistance is not within specification. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__overhaul).
To test the rotor for a grounded circuit, use an ohmmeter to check for no continuity between each slip ring and the rotor. (Scheme 7) Replace rotor if continuity exists. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__overhaul).
Using caliper, measure outside diameter of each slip ring. See «ROTOR SPECIFICATIONS»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators) table. Replace rotor if outside diameter is not within specification. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__overhaul).

Application			Specification
Rotor Resistance
Esteem, Grand Vitara & Vitara (85-Amp Generator)			2.9 Ohms
Swift			3.1-3.5 Ohms
Vitara (60- & 70-Amp Generator)			2.5-2.9 Ohms
Slip Ring Outside Diameter
Esteem
Standard			.567" (14.40 mm)
Wear Limit			.551" (14.00 mm)
Grand Vitara & Vitara (85-Amp Generator)
Standard			.557"-.567" (14.20-14.40 mm)
Wear Limit			.504" (12.80 mm)
Swift & Vitara (Except 85-Amp Generator)			(1)
(1) Information is not available from manufacturer.

(1)	Information is not available from manufacturer.

ROTOR SPECIFICATIONS

Scheme 7

STATOR

To test stator for an open circuit, use ohmmeter to check for continuity between each electrical lead on the stator. (Scheme 8)
Continuity should exist between all electrical leads. Replace stator if no continuity exists between any electrical leads. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__overhaul).
To test stator for a grounded circuit, use ohmmeter to check for continuity between each electrical lead on the stator and the outside of the stator. (Scheme 8) Replace stator if continuity exists between any electrical lead and the outside of the stator. See «OVERHAUL»(/suzuki/grand-vitara/i-1997-2001/remont/charging-system/#generators-regulators__overhaul).