Alternator & Regulator Suzuki Swift II

DESCRIPTION

Alternators are conventional 3-phase alternators utilizing 3 positive and 3 negative diodes to rectify current. Internal Integrated Circuit (IC) voltage regulator controls charging system voltage. (Scheme 1)

Scheme 1

BELT ADJUSTMENT

BELT DEFLECTION SPECIFICATIONS

ON-VEHICLE TESTING

PRELIMINARY INSPECTION

1. If battery is overcharged go to «BENCH TESTING»(/suzuki/swift/ii-1989-1995/remont/charging-system/#alternator-regulator) . If battery is undercharged, check alternator wiring harness connections and drive belt tension. Ensure battery is fully charged. Connect a voltmeter to alternator "B" terminal and ground. Connect ammeter positive lead to alternator "B" terminal. Connect ammeter negative lead to positive side of battery and start engine.
2. With all accessories off, increase engine speed from idle to 2000 RPM and read meters. Voltmeter reading should be 14.2-14.8 volts at 77°F (25°C) for Samurai and Swift. For Sidekick, reading should be 14.4-15.0 volts at 68°F (20°C). Voltage reading will vary depending on regulator case temperature. Ammeter reading should be about 10 amps. Turn engine off.
3. If voltage is higher than standard value, replace IC regulator on Samurai and Swift. On Sidekick, check brush ground. See «BENCH TESTING»(/suzuki/swift/ii-1989-1995/remont/charging-system/#alternator-regulator) . If brush ground is okay, replace IC regulator.
4. On Samurai and Swift, if voltage is lower than standard value, ground "F" terminal and start engine. If voltage at "B" terminal is greater than standard value, replace IC regulator. If voltage is less than standard value, go to «BENCH TESTING»(/suzuki/swift/ii-1989-1995/remont/charging-system/#alternator-regulator) .
5. Load test all models with engine running at 2000 RPM and headlights and heater blower motor on. If current is less than 20 amps, go to «BENCH TESTING»(/suzuki/swift/ii-1989-1995/remont/charging-system/#alternator-regulator) .

BRUSHES

1. Check brushes for cracks. Measure brush length. Standard measurement for Samurai and Swift is .43" (11.0 mm). Minimum length for Samurai is .20" (5 mm) and for Swift .18" (4.5 mm). For Sidekick, standard measurement is .63" (16.0 mm). Minimum length is .08" (2.0 mm). Ensure brushes slide smoothly in holders.
2. If damaged or worn, replace brushes and brush holder. Install NEW springs when replacing brushes.

CONDENSER

Using an ohmmeter set to read capacitance, check capacity of condenser in regulator. (Scheme 2) Condenser capacitance should be.5 microfarads. If not, replace the regulator.

Scheme 2

RECTIFIER

1. Using an ohmmeter, check for continuity between ground and "B" terminal. Connect one lead of ohmmeter to "B" terminal and other to ground. Swap leads and recheck for continuity. (Scheme 3)or (Scheme 4).

Scheme 3

Scheme 4

1. Check continuity between upper and lower rectifier bodies and each diode lead as shown. Reverse ohmmeter probes, ensuring one-way continuity at each diode.
2. Ensure one-way continuity between both leads of diode trio. Replace rectifier if check is not satisfactory. (Scheme 4)
3. In one direction there should be approximately 10 ohms of resistance. In other direction reading should be an infinite, indicating no continuity. If not, replace rectifier.

ROTOR

1. Check rotor for open field windings by using an ohmmeter across slip rings. (Scheme 5) Resistance should be 2.8-3.0 ohms.
2. Check rotor for shorts to ground by connecting ohmmeter between slip ring and rotor shaft. Ohmmeter should show no continuity. Check slip rings for wear or pitting. Turn rotor on lathe (if necessary). Check bearing and replace (if necessary).

Scheme 5

STATOR

1. Connect ohmmeter between 2 stator leads. (Scheme 6) Ensure continuity exists between all stator leads. Connect ohmmeter between each stator lead and metal core. Ohmmeter should show no continuity. If continuity is indicated, replace stator.

Scheme 6

CHARGING SYSTEM

CHARGING SYSTEM TROUBLE SHOOTING

Samurai

Disconnect negative battery cable. Disconnect alternator lead wires. Remove brakeline from radiator undercover and remove undercover. Remove alternator mounting bolts and drive belt adjusting bolt. Remove alternator. To install, reverse removal procedure. Adjust belt. See BELT DEFLECTION SPECIFICATIONS table under ADJUSTMENTS.

Sidekick

Disconnect negative battery cable. Disconnect alternator lead wires. Remove canister and canister mounting bracket. Remove alternator mounting bolts and drive belt adjusting bolt. Remove alternator. To install, reverse removal procedure. Adjust belt. See BELT DEFLECTION SPECIFICATIONS table under ADJUSTMENTS.

Swift

Disconnect negative battery cable. Remove air cleaner assembly including airflow meter and airflow meter outlet hose. Disconnect alternator lead wires and cover bolt. Remove alternator drive belt adjusting bolt and alternator cover. Remove mounting bolts and drive belt and remove alternator downward. To install, reverse removal procedure. Adjust belt. See BELT DEFLECTION SPECIFICATIONS table under ADJUSTMENTS.

Disassembly

1. Remove "B" terminal retaining nut. Remove "B" terminal insulator. Remove 3 rear cover retaining nuts. Remove rear cover. Loosen and remove 2 regulator mounting screws and 3 brush holder screws. Remove regulator and brush holder. (Scheme 8)
2. Remove 4 stator coil terminal retaining screws. Remove rectifier holder with I.C. regulator. Loosen and remove 4 rear housing retaining nuts. Loosen alternator pulley retaining nut.
3. Pull off alternator pulley. Using plastic mallet, lightly tap rotor from front housing. Remove 4 front bearing retaining screws and front bearing (if necessary). Using a bearing puller, pull rear bearing from rotor (if necessary).

Inspection

1. Check brushes for cracks. Using a vernier caliper, measure brush length. Standard measurement is .43" (11.0 mm). Minimum length is .18" (4.5 mm). Ensure brushes slide smoothly in holders.
2. If damaged or worn, replace brushes and brush holder. Install NEW springs when replacing brushes.

Reassembly

1. To reassemble, reverse disassembly procedure. To install new bearings on either rotor or front housing, use a hydraulic press.
2. Ensure that stator terminal insulation is properly installed. Install alternator pulley. Tighten pulley nut to 69-94 ft. lbs. (95-130 N.m).

1. Scribe mark on front and rear housing for reassembly reference. Remove housing bolts. Using a 200-watt soldering iron, heat rear bearing to 120-140° F (50-60° C). Insert lever between stator core and front housing and separate alternator halves.
2. Mount alternator rotor in a soft-jawed vise. Remove pulley nut and pulley. Remove rotor from front housing. (Scheme 9) Remove 4 retaining screws, front bearing retainer plate and front bearing from front housing (if required).
3. If rear bearing requires replacement, mount rotor in bearing separator plate and remove bearing using a hydraulic press. Remove 4 stator retaining screws, battery terminal nut and stator from alternator rear housing. If brushes require replacement, remove wire cover from brush holder and remove brush wires from regulator using a soldering iron.

1. Check brushes for cracks. Using a vernier caliper, measure brush length. Standard measurement is .63" (16.0 mm). Minimum length is .08" (2.0 mm). Ensure brushes slide smoothly in holders.
2. If damaged or worn, replace brushes and brush holder. Install NEW springs when replacing brushes.

1. Install new bearings on either rotor or front drive housing (if required) using a hydraulic press. Install alternator pulley. Tighten pulley nut to 44-51 ft. lbs. (60-70 N.m).
2. Solder brushes to regulator in proper direction. (Scheme 7) Install new brush springs. Install brushes into brush holder and slide appropriate sized piece of wire through holes in brush holder to retain brushes. Install brush holder so that wire protrudes through rear of alternator case.
3. Ensure that stator terminal insulation is properly installed and install stator. Heat rear bearing as in step 1) and assemble alternator halves, making sure to align scribe marks.

Scheme 7

Scheme 8

Scheme 9

See also:
• BENCH TESTING