Generators & Regulators Suzuki Grand Vitara I рестайлинг

IDENTIFICATION

GENERATOR IDENTIFICATION

GENERATOR DESCRIPTION

The basic charging system is the Integral Regulator Charging System. The internal components are connected electrically. (Scheme 1)or (Scheme 2).

Scheme 1

Scheme 2

CHARGING SYSTEM CIRCUIT

The generator features a solid state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the rear housing. The regulator voltage setting cannot be adjusted. The generator rotor bearings contain enough grease to eliminate the need for periodic lubrication. Two brushes carry current through the two slip rings to the field coil mounted on the rotor, and under normal conditions will provide long period of attention free service. The stator windings are assembled inside a laminated core that forms part of the generator frame. A rectifier bridge connected to the stator windings contains diodes, and electrically changes the stator AC voltages to a DC voltage which appears at the generator output terminal. The neutral diodes serve to convert the voltage fluctuation at the neutral point to direct current for increasing the generator output. (Scheme 3)

Scheme 3

GENERATOR SYMPTOM DIAGNOSIS

For charging circuit wiring diagram for generator connection (Scheme 3) To avoid damage, always follow these precautions

Scheme 4

No-Load Check

Note. Turn off switches of all accessories (wiper, heater etc.).

Run engine at idle up to 2000 RPM. Read meters. Amperage should be 10 amps (maximum). Voltage should be 14.4-15.0 volts at 68°F (20° C) for 70A alternator or 14.2-14.8 volts at 68°F (20° C) for 80A/105A alternators.

Note. Consideration should be taken that voltage will differ somewhat with regular case temperature. (Scheme 5)or (Scheme 6).

Scheme 5

Scheme 6

If voltage is higher than standard value, check ground of brushes. If the brushes are not grounded, replace IC regulator. If voltage is below or in standard value

1. Run engine at 2000-2500 rpm soon after starting engine.
2. Read maximum value on ammeter immediately. If current is less than 49A (70A model) or 56A (80A/105A model) repair or replace the generator (70A). Ground "F" terminal and start engine. Measure voltage at "B" terminal (80A/105A). (Scheme 7)

If voltage is higher than standard value, it is considered that generator itself is good but IC regulator has been damaged, replace IC regulator. If voltage is lower than standard value, generator itself has problem, check the generator (80A/105A).

Scheme 7

Load Check (80A/105A)

Run engine at 2000 rpm and turn on head light and heater motor. Measure current and if it is less than 30 A, repair or replace generator.

BRUSH & BRUSH HOLDER

Check each brush for wear by measuring its length. If brush is found worn down to service limit, replace brush. See GENERATOR SPECIFICATIONS. (Scheme 8)or (Scheme 9).

Scheme 8

Scheme 9

70A

Testing information for 70A is not available from manufacturer.

80A/105A

1. Check that drive and bearing is not rough or worn. (Scheme 40)
2. Check that end housing bearing is not rough or worn. (Scheme 39)

Using capacitor tester, check capacity of condenser, located on rectifier. (Scheme 10) Replace rectifier if condenser capacity is not.5 uF.

Scheme 10

Testing information for 80A/105A model is not available from manufacturer.

1. Using ohmmeter, check continuity between each of upper and lower rectifier bodies and each diode lead (2). Check both directions by reversing probes of ohmmeter and there should be only one way continuity in each case. If check result is not satisfactory, replace the rectifier (1).
2. In the same manner as described in above step 1, check that there is only one way continuity between both leads of diode trio. (Scheme 11)

Scheme 11

1. Positive rectifier (Scheme 12)Using an ohmmeter, connect one tester probe to the "B" terminal (1) and the other to each rectifier terminal (2). Reverse the polarity of the tester probes and repeat step No. 1. Check that one shows continuity and the other shows no continuity. If there is continuity, replace rectifier.
2. Negative rectifier Using an ohmmeter, connect one tester probe to each negative terminal (1) and the other to each rectifier terminal (2). (Scheme 12) Reverse the polarity of the tester probes and repeat step No. 1. Check that one shows continuity and the other shows no continuity. If there is continuity, replace the rectifier.

Scheme 12

ROTOR

1. To test rotor for an open circuit, use ohmmeter to check for continuity between slip rings of rotor. If there is no continuity, replace the rotor (1). (Scheme 13)
2. Using ohmmeter, check that there is no continuity between slip ring and rotor core. If there is continuity, replace rotor (1). (Scheme 13)
3. Check slip rings for roughness or scoring. If rough or scored, replace the rotor.
4. Using a vernier caliper, measure the slip ring diameter. If the diameter is less than minimum, replace the rotor (80A/105A). (Scheme 14)

Scheme 13

Scheme 14

STATOR

1. To test stator for an open circuit, use ohmmeter to check all leads for continuity. If there is no continuity, replace the stator (1). (Scheme 15)or (Scheme 16).
2. Using Ohmmeter, check that there is no continuity between coil leads (2) and stator core (1). If there is continuity, replace stator. (Scheme 15)or (Scheme 16).

Scheme 15

Scheme 16

Removal (70A)

1. Disconnect negative cable at battery.
2. Loosen generator adjusting bolt (1) and pivot bolt (2). (Scheme 17)
3. Slacken belt by displacing fan pulley.
4. Remove cooling fan. Just detach the fan/clutch from fan pulley.
5. Remove cooling fan belt (3).

Scheme 17

Installation (70A)

1. Install belt to fan pulley and crankshaft pulley.
2. Install cooling fan.
3. Adjust belt tension. See «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-162940) article in ENGINES.
4. Tighten the adjusting bolt and pivot bolt.
5. Connect negative cable at battery.

Removal (80A/105A)

1. Disconnect negative cable at battery.
2. Loosen Power Steering P/S pump drive belt adjusting bolt and remove P/S pump belt.
3. Loosen generator adjusting bolt (1) and pivot bolt. (Scheme 19)
4. Slacken belt by displacing generator and remove it.

Installation (80A/105A)

1. Install belt to water pump pulley, crankshaft pulley and generator pulley. Install P/S pump drive belt.
2. Adjust belt tension. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/suzuki/grand-vitara/i-2000-2006/remont/accessory-drive-belts/#specifications-drive-belt-routing) article in ENGINES.
3. Tighten adjusting bolt and pivot bolt.
4. Connect negative cable at battery.

1. Loosen tensioner by turning the tensioner pulley (2) clockwise.
2. While holding the tensioner and belt loose, remove generator belt (1). (Scheme 18)

Scheme 18

1. Loosen tensioner by turning the tensioner pulley (2) clockwise.
2. While holding the tensioner, install the generator belt (1). (Scheme 18)

Removal

1. Disconnect negative cable at battery.
2. Disconnect generator lead wire ("B" terminal wire) and coupler from generator.
3. Remove generator belt. See «GENERATOR BELT»(/suzuki/grand-vitara/i-2000-2006/remont/charging-system/#generators-regulators) (70A) or «COOLING FAN»(/suzuki/grand-vitara/i-2000-2006/remont/charging-system/#generators-regulators) (80A/105A).
4. Remove generator drive belt adjusting bolt and generator mounting bolt.
5. Remove generator.

Installation

1. Mount generator on the generator bracket.
2. Tighten generator bolts (upper bolt (1), lower bolt (2)) to specification. See «TORQUE SPECIFICATIONS»(/suzuki/grand-vitara/i-2000-2006/remont/charging-system/#generators-regulators__torque-specifications).
3. Install generator belt. See «GENERATOR BELT»(/suzuki/grand-vitara/i-2000-2006/remont/charging-system/#generators-regulators) (70A) or «COOLING FAN»(/suzuki/grand-vitara/i-2000-2006/remont/charging-system/#generators-regulators) (80A/105A).
4. Install cooling fan belt (70A). See «COOLING FAN»(/suzuki/grand-vitara/i-2000-2006/remont/charging-system/#generators-regulators).
5. Connect "B" terminal wire (3) and coupler to generator. Tighten "B" terminal outer nut (b) to the specification. (Scheme 19)
6. Install canister (70A).
7. Connect negative cable at battery.

Scheme 19

Use exploded view of generator for overhaul. (Scheme 20)or (Scheme 21).

Scheme 20

Scheme 21

Disassembly (70A)

1. For easier reassembly, provide match marks (3) on both front housing (1) and rear housing (2) before separating them. (Scheme 22)
2. Remove housing bolts (1) from generator. (Scheme 23)
3. With lever (4) inserted between stator core (2) and front housing (3), separate generator into front (3) and rear (1) sides. (Scheme 24)
4. Loosen pulley nut (1) by using vise (4) and take off pulley.
5. Remove rotor (2) from front housing. (Scheme 25)
6. When removing front bearing, remove bearing retainer screws (2) and retainer. (Scheme 26)
7. When removing rear bearing (1), use oil hydraulic press "2". (Scheme 27)
8. Remove (3) screws (1) and generator "B" terminal nut (2). (Scheme 28)
9. Unsolder stator leads (1) and remove stator from rear housing and regulator assembly. (Scheme 29)
10. To remove brush, remove holder cover from brush holder and disconnect the brush wire from regulator terminal by using soldering iron. (Scheme 30)

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Reassembly (70A)

1. Assemble in the reverse order of disassembly. Be sure to install brushes (2) in the proper direction and solder brush wires and stator leads. (Scheme 29)and (Scheme 30).
2. Tighten generator pulley nut (1) to specifications. See «TORQUE SPECIFICATIONS»(/suzuki/grand-vitara/i-2000-2006/remont/charging-system/#generators-regulators__torque-specifications).
3. Push brushes into brush holder. Support brushes by inserting appropriate wire (2) from hole of rear housing (1). (Scheme 31)
4. After assembling generator, ensure that rotor turns smoothly.

Scheme 30

Diassembly (80A/105A)

1. Remove "B" terminal inner nut (3) and insulator (2).
2. Remove rear end cover (1). (Scheme 32)
3. Remove 2 screws (3) and pull out brush holder assembly (4).
4. Remove 3 screws (1) and IC regulator (2).
5. Remove brush holder cover from brush holder. (Scheme 33)
6. Remove 4 screws, 1 bolt and rectifier (1). (Scheme 34)
7. Remove 4 rubber insulators (1). (Scheme 35)
8. Hold shaft by using hexagonal box wrench (2) and remove pulley nut, and pull out pulley (1). (Scheme 36)
9. Remove 4 rear end frame nuts (3).
10. Drive out rear end frame (1) with tapping rotor shaft (2) lightly by using plastic hammer (4).
11. Separate rear end frame (1) from rotor evenly by using plastic hammer (4). (Scheme 37)
12. If required, use bearing puller (2) to remove end housing bearing (1) and bearing cover (3). (Scheme 38)
13. If required, remove 4 screws, retainer plate (2) and drive out drive end bearing (3).
14. If required, remove stud bolts (1) and then pull out stator (4). (Scheme 40)

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Reassembly (80A/105A)

1. If end housing bearing (1) is removed, install it.
2. Check end housing bearing (1) turns smoothly. (Scheme 39)
3. If stator (4) is removed, install stator (4) and tighten stud bolts (1).
4. If drive end bearing (3) is removed, install it.
5. Check drive end bearing (3) turns smoothly. If OK, install drive end bearing retaining plate (2). (Scheme 40)
6. Place drive end frame (2) on pulley, and install rotor (1) to drive end frame (2). (Scheme 41)
7. Install rear frame (1) to drive end frame (2). (Scheme 42)
8. Tighten 4 nuts to the specifications. See «TORQUE SPECIFICATIONS»(/suzuki/grand-vitara/i-2000-2006/remont/charging-system/#generators-regulators__torque-specifications).
9. Install pulley (1) and tighten pulley nut with holding shaft by using hexagonal box wrench (2) to the specifications. (Scheme 36)
10. Install 4 rubber insulators (1). (Scheme 35)
11. Install rectifier (1). (Scheme 34)
12. Install brush holder cover (1) to brush holder (2). (Scheme 43)
13. Place the IC regulator (1) together with the brush holder (2) horizontally on the rear end frame (3).
14. Install the 5 screws until there is a clearance of approximately.04" (1 mm) between the brush holder (2) and connector. (Scheme 44)
15. Install rear end cover (1) and terminal plate (4).
16. Install insulator (2) and tighten "B" terminal inner nut (3) to the specified torque. See «TORQUE SPECIFICATIONS»(/suzuki/grand-vitara/i-2000-2006/remont/charging-system/#generators-regulators__torque-specifications). (Scheme 45)
17. Ensure that rotor turns smoothly. see scheme 46

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

GENERATOR SPECIFICATIONS

For generator specifications for Grand Vitara models, see Generator in GRAND VITARA SPECIFICATIONS INDEX table under SPECIFICATIONS INDEX in SPECIFICATIONS INDEX article.

For generator specifications for Vitara models, see Generator in VITARA SPECIFICATIONS INDEX table under SPECIFICATIONS INDEX in SPECIFICATIONS INDEX article.

For generator specifications for XL-7 models, see SPECIFICATIONS INDEX .

TORQUE SPECIFICATIONS

For torque specifications for Grand Vitara models, see Generator in GRAND VITARA SPECIFICATIONS INDEX table under SPECIFICATIONS INDEX in SPECIFICATIONS INDEX article.

For torque specifications for Vitara models, see Generator in VITARA SPECIFICATIONS INDEX table under SPECIFICATIONS INDEX in SPECIFICATIONS INDEX article.

For torque specifications for XL-7 models, see SPECIFICATIONS INDEX .

WIRING DIAGRAMS

1. For wiring diagrams on 2003 Vitara (2.0L) models, see «SYSTEM WIRING DIAGRAMS»(ref-159050) article in ELECTRICAL.
2. For wiring diagrams on 2003 Grand Vitara models, see «SYSTEM WIRING DIAGRAMS»(ref-159049) article in ELECTRICAL.
3. For wiring diagrams on 2003 XL-7 models, see «SYSTEM WIRING DIAGRAMS»(ref-159051) article in ELECTRICAL.

See also:
• SPECIFICATIONS & DRIVE BELT ROUTING
• GENERATOR SPECIFICATIONS
• GENERATOR BELT
• TORQUE SPECIFICATIONS