1999 SUZUKI GRAND VITARA Generator

MAINTENANCE AND LUBRICATION 0B-5
Maintenance Service
Engine and Emission Control
ITEM 1-1
Drive belt inspection and replacement
WATER PUMP AND GENERATOR DRIVE BELT INSPEC-
TION
1) Disconnect negative (–) cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If any defect exists, replace.
Check belt for tension.
Water pump and generator belt tension “a”: 9-11 mm
(0.35- 0.43 in.) deflection under 100 N, 10 kg or 22 lb pres-
sure
3) If belt is too tight or too loose, adjust it to specification by
adjusting alternator position.
4) Tighten alternator adjusting bolt and pivot bolts.
5) Connect negative (–) cable to battery.
WATER PUMP AND GENERATOR DRIVE BELT REPLACE-
MENT
Replace belt. Refer to Section 6B for replacement procedure of
pump belt.WARNING:
All inspection and replacement are to be performed with
ENGINE NOT RUNNING.
NOTE:
When replacing belt with a new one, adjust belt tension
to 7 - 9 mm (0.28 - 0.35 in.)
1. Crankshaft pulley
2. Water pump pulley
3. 100 N, 10 kg or 22 lb

1B-14 AIR CONDITIONING (OPTIONAL)
Wiring Circuit
ACG
LT GRN
PNK
PNK
BLKORN
BLK
YEL/GRNRED/BLKBLK/WHT
BLU/WHTPNK/BLK
PNK/GRN
RED/BLK
WHT/RED
YEL/GRN
YEL/BLU
A/C
RED/BLU
RED/BLU
RED/BLKBLK
BLU/ORN
BLU/WHT
BLU/WHT
PNK
PNK/BLU
BLK
PNK/WHT
YEL/BLK
GRY/WHT
GRN/BLK
BLK/WHT
RED/BLK
YEL/GRN
BLK
BLK
BLK
YEL/BLK
YEL/GRN
YEL/GRNBLU/GRN
BLU/YELBLUBLU/BLK
BLU/BLK
17
21
22 18
16
15
19
2026 25 24 23
14
12
29
3
4
7
33 30
31
32
28
27
1213
10
11
35 349
856
A
1. Front blower motor main relay 10. Compressor relay 19. Battery 28. Solenoid valve relay
2. Front blower motor 11. Compressor 20. Generator 29. Rear blower motor relay
3. Front blower motor resistor 12. Condenser cooling fan motor
relay21. Ignition main fuse 60 A 30. Rear blower motor resistor
4. Front blower motor switch 13. Condenser cooling fan motor 22. Heater/A/C main fuse 60 A 31. Rear blower motor
5. A/C controller 14. Fuse box 23.“IG METER” fuse 20 A 32. Rear blower motor switch
6. ECM (PCM) 15.“A/C” fuse 25 A 24.“REAR DEFG” fuse 25 A 33. Rear A/C main switch
7. Heater mode control switch 16. Ignition switch 25.“REAR BLOW” fuse 20A 34. Rear A/C evaporator temperature con-
troller
8. Dual (refrigerant) pressure switch 17. Main fuse box 26.“FRONT BLOW” fuse 30A 35. Rear A/C evaporator temperature sensor
9. A/C evaporator thermistor
(A/C evaporator temperature sensor)18. Battery main fuse 100 A 27. Solenoid valve [A] : Rear A/C wiring circuit (if equipped)

ENGINE MECHANICAL (H27 ENGINE) 6A2-27
12) Disconnect the following electric lead wires :
•Injector wire coupler
•CMP sensor coupler
•Ignition coil couplers
•CKP sensor coupler
•MAP sensor coupler
•TP sensor (1) coupler
•IAC valve (2) coupler
•Earth wire (3) from surge tank
•EVAP canister purge valve coupler
•EGR valve coupler
•Oxygen sensor -1 and -2 couplers referring to “Exhaust Man-
ifold” in this section
•Coolant temperature sensor coupler
•Knock sensor coupler
•Generator wires
•Starter wires
•Oil pressure wire
•P/S pump wire
•Earth wire from generator bracket
•Engine block heater (if equipped)
13) Remove clamps and brackets.
14) Disconnect the following hoses :
•Heater hose from heater water pipe
•Heater hose from water outlet cap
•EVAP canister hose from canister pipe
•Brake booster vacuum hose
15) Remove EVAP canister purge valve (5).
16) Disconnect the following hoses at the location shown in the
figure :
•Fuel feed hose (1) from fuel feed pipe
•Fuel return hose from (2) fuel return pipe
17) Remove P/S pump assembly. Refer to “POWER STEERING
PUMP” in Section 3B1.
18) Remove A/C compressor assembly. Refer to “COMPRES-
SOR ASSEMBLY” in Section 1B.
19) Remove steering shaft lower assembly. Refer to “STEERING
LOWER SHAFT ASSEMBLY” in Section 3C1.
20) Raise vehicle.
21) Remove front differential housing with differential from chas-
sis if equipped. Refer to “DISMOUNTING” in Section 7E.
22) Remove exhaust No.1 pipe. Refer to “EXHAUST MANI-
FOLD” in this section.
23) Remove exhaust manifold stiffener from transmission.
4. Clamp bracket
6. EGR valve
7. Heater hose
2
14
3
75
6

CHARGING SYSTEM 6H-1
6H
SECTION 6H
CHARGING SYSTEM
CONTENTS
General Description ....................................... 6H-2
Generator ..................................................... 6H-2
Unit Repair Overhaul ..................................... 6H-3
Generator Assembly .................................... 6H-3
Inspection ................................................. 6H-3Specifications................................................. 6H-6
Battery.......................................................... 6H-6
Generator ..................................................... 6H-6
Tightening Torque Specification .................. 6H-6

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in Section 10B in order to confirm whether you are performing service on or
near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in Section 10B before performing service on or around the air
bag system components or wiring. Failure to follow WARNINGS could result in unintentional activa-
tion of the system or could render the system inoperative. Either of these two conditions may result
in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.

6H-2 CHARGING SYSTEM
General Description
Generator
WIRING CIRCUIT
B : Generator output (Battery terminal) L : Lamp terminal 5. Stator core 10. Rear end frame
D : Dummy terminal 1. Pulley 6. Field coil 11. Drive end frame
E : Ground 2. Pulley nut 7. Rectifier
F : Field coil terminal 3. Rotor fan 8. Brush
IG : Ignition terminal 4. Stator coil 9. Regulator
1. Generator with regulator assembly 3. Stator coil 5. Field coil (rotor coil) 7. Main switch
2. I.C. regulator 4. Diode 6. Charge indicator light 8. Battery

CHARGING SYSTEM 6H-3
Unit Repair Overhaul
Generator Assembly
Inspection
Rotor
•Using ohmmeter, check for continuity between slip rings of
rotor. If there is no continuity, replace rotor.
Standard resistance between slip rings of rotor
: 1.6 – 2.0 Ω
ΩΩ Ω at 20°C (68°F)
1. Pulley nut 6. Driver end bearing 11. Wave washer 16. Regulator 21. Terminal plate
2. Pulley 7. Bearing retainer 12. Rear end frame 17. Brush
3. Drive end bearing 8. Rotor 13. Seal plate 18. Brush holder
4. Stator 9. End housing bearing 14. Rectifier 19. Brush holder cover
5. Stud bolt 10. Bearing cover 15. Insulator 20. Rear end cover

6H-6 CHARGING SYSTEM
Specifications
Battery
Generator
Tightening Torque Specification
Battery type 55D23L 75D23L 95D26L
Rated capacity AH/5HR, 12 Volts 48 52 66
Electrolyte L (US/Imp.pt) 3.9 (8.24/6.86) 3.9 (8.24/6.86) 4.0 (8.53/7.04)
Electrolyte S.G. 1.28 when fully charged at 20°C (68°F)
Type 105 A type
Rated voltage 12 V
Nominal output 105 A
Permissible max. speed 18000 r/min.
No-load speed 1150 r/min (rpm)
Setting voltage 14.2 to 14.8 V
Permissible ambient temperature–30 to 90 °C (–22 to 194 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Fastening partTightening torque
Nm kg-m lb-ft
Body ground bolt 8 0.8 6.0
Generator mounting bolts and nut 23 2.3 16.5
“B” terminal inner nut 3.6 0.37 3.0
“B” terminal outer nut 8 0.8 6.0
Generator pulley nut 111 11.2 81.5
Rear end frame nuts 4.5 0.45 3.5
Rear end cover nuts 4.5 0.45 3.5
Stator stud bolts 9.8 1.0 7.0
Drive end bearing plate screws 3.0 0.30 2.2
Rectifier screws 3.0 0.30 2.2
Regulator and brush holder screws 2.0 0.20 1.5
Terminal plate bolt 3.9 0.39 3.0

INSTRUMENTATION/DRIVER INFORMATION 8C-3
COMBINATION METER INTERNAL CIRCUITS
COMBINATION METER COUPLERS
[A] : Coupler A [B] : Coupler B [C] : Coupler C
1. To Cruise control module (if equipped) GRY/YEL 1. To door switch (drive side) BLK/BLU 1. To ground BLK
2. Blank–2. To transmission range switch
(A/T vehicle only, if equipped) LGRN/BLU 2. To ECM (PCM for A/T vehicle) BRN
3. To ignition switch BLK/WHT 3. To transmission range switch
(A/T vehicle only, if equipped) 2GRN/ORN 3. To ignition switch PPL/RED
4. Blank–4. To transmission range switch
(A/T vehicle only, if equipped) DYEL/GRN 4. To brake fluid level switch RED/BLK
5. To ABS control module (if equipped) BLU/ORN 5. To transmission range switch
(A/T vehicle only, if equipped) NORN/BLU 5. To parking brake switch PPL
6. To PCM (A/T vehicle only) GRY/BLU 6. To transmission range switch
(A/T vehicle only, if equipped) PORN/GRN 6. To seat belt switch GRY/RED
7. To ABS control module (if equipped) BRN 7. To transmission range switch
(A/T vehicle only, if equipped) RRED 7. To generator WHT/RED
8. To VSS BLU/YEL 8. To illumination control module RED/GRN 8. To engine oil pressure switch YEL/BLK
9. To combination switch GRN/RED 9. To PCM (A/T vehicle only) WHT/BLK 9. To combination switch RED/YEL
10. To air bag SDM BLU 10. To ECT sensor YEL/WHT 10. To ignition switch BLU/RED
11. To main fuse WHT/BLU 11. To fuel level gauge BLU/WHT
12. To fuse box WHT 12. To ground BLU/YEL
13. To combination switch RED 13. To combination switch GRN/YEL
14. To immobilizer control module
(if equipped)PPL
15. To ECM (PCM for A/T vehicle) PPL/YEL
16. To ECM (PCM for A/T vehicle) ORN/BLK
P R N D 2 LCRUISEPOWER4WDSPEED
METERTACHO
METERFUEL
METERTEMP.
METER
A-11
A-13 A-8 B-12 B-11 C-8 A-15 A-6 A-1 B-9 A-16 A-14 C-7 C-1 A-10 C-3 C-4 C-5 A-7 A-5 B-8 B-1B-10 C-2 A-12 A-3B-13 B-2 B-3 B-4 B-5 B- B-6 C-9 C-10 A-9ABS circuit EBD circuit Air bag circuit
or ABS or BRAKE
if equipped
or CHECK
ENGINE
NOTE:
Terminal arrangement of coupler viewed from harness side.