2005 SUZUKI JIMNY Service Workshop Manual

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Diagnosis
Battery
COMMON CAUSES OF FAILURE
A battery is not designed to last indefinitely; however, with proper
care, it will provide many years of service. If the battery performs
satisfactorily during test but fails to operate properly for no appar-
ent reason, the followings are some factors that may point to the
cause of trouble:
Accessories left on overnight or for an extended period with-
out the generator operating.
Slow average driving speeds for short periods.
Electrical load exceeding generator output particularly with
addition of after market equipment.
Defects in charging system such as high resistance, slipping
drive belt, loose generator output terminal, faulty generator
or voltage regulator. Refer to “Generator” in this “Diagnosis”
section.
Battery abuse, including failure to keep battery cable termi-
nals clean and tight or loose battery hold down.
Mechanical problems in electrical system such as shorted or
pinched wires.
VISUAL INSPECTION
Check for obvious damage, such as cracked or broken case or
cover, that could permit loss of electrolyte. If obvious damage is
noted, replace battery. Determine cause of damage and correct
as needed.
HYDROMETER TEST
The direct method of checking the battery for state of charge is to
carry out a high rate discharge test, which involves a special pre-
cise voltmeter and an expensive instrument used in the service
shops, but not recommendable to the user of the vehicle.
At 20 °C of battery temperature (electrolyte temperature):
The battery is in FULLY CHARGED STATE if the electrolyte
S.G. is 1.280.
The battery is in HALF CHARGED STATE if the S.G. is
1.220.
The battery is in NEARLY DISCHARGED STATE if the S.G.
is 1.150 and is in danger of freezing.
As the S.G. varies with the temperature, if battery temperature is
not at 20 °C (68 °F), you have to correct your S.G. reading (taken
with your hydrometer) to the value at 20 °C (68 °F) and apply the
corrected S.G. value to the three-point guide stated value. For the
manner of correction, refer to the graph showing the relation
between S.G. value and temperature.

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How to use the temperature-corrected state-of-charge
graph
Suppose your S.G. reading is 1.28 and the battery temperature is
–5 °C (23 °F). Locate the intersection of the –5 °C line and the
1.28 S.G. line.
The intersection is within the “A” zone (shaded area in the graph)
and that means CHARGED STATE.
To know how much the battery is charged, draw a line parallel to
the zone demarcation line and extend it to the right till it meets
with the percentage scale. In the present example, the line meets
at about 85% point on the percentage scale. Therefore, the bat-
tery is charged up to the 85% level.
Generator
Trouble in charging system will show up as one or more of follow-
ing conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow cranking or
indicator dark.
3) An overcharged battery as evidenced by excessive spewing
of electrolyte from vents.
Noise from generator may be caused by a loose drive pulley,
loose mounting bolts, worn or dirty bearings, defective diode, or
defective stator.
FAULTY INDICATOR LAMP OPERATION
CAUTION:
Do not mistake polarities of IG terminal and L terminal.
Do not make a short circuit between IG and L termi-
nals. Always connect these terminals through a lamp.
Do not connect any load between L and E.
When connecting a charger or a booster battery to
vehicle battery, refer to this section describing battery
charging.
B: Generator output (Battery terminal)
E: Ground
IG: Ignition terminal
L: Lamp terminal
Condition Possible Cause Correction
Charge light does not
light with ignition ON
and engine offFuse blown Check fuse.
Light burned out Replace light.
Wiring connection loose Tighten loose connection.
IC regulator or field coil faulty Check generator.
Charge light does not go
out with engine running
(battery requires fre-
quent recharging)Drive belt loose or worn Adjust or replace drive belt.
IC regulator or generator faulty Check charging system.
Wiring faulty Repair wiring.

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UNDERCHARGED BATTERY
This condition, as evidenced by slow cranking or indicator clear
with red dot can be caused by one or more of the following condi-
tions even though indicator lamp may be operating normal.
Following procedure also applies to cars with voltmeter and
ammeter.
1) Make sure that undercharged condition has not been caused
by accessories left on for extended period of time.
2) Check drive belt for proper tension.
3) If battery defect is suspected, refer to BATTERY section.
4) Inspect wiring for defects. Check all connections for tight-
ness and cleanliness, battery cable connections at battery,
starting motor and ignition ground cable.
5) Connect voltmeter and ammeter as shown in the figure.
6) Measure current and voltage.
No-load Check
1) Run engine from idling up to 2,000 rpm and read meters.
Standard current
10 A maximum
Standard voltage
14.4 – 15.0 V (at 20 °C, 68 °F)
Higher Voltage
If voltage is higher than standard value, check ground of brushes.
If brushes are not grounded, replace IC regulator.
Lower Voltage
If voltage is below or in standard value, increase engine speed up
to 2,000 – 2,500 rpm soon after starting engine, and read maxi-
mum value on ammeter immediately.
If current is less than 49 A, repair or replace generator.NOTE:
Use fully charged battery.
1. Generator
2. Ammeter (between generator (B) terminal and battery (+) terminal)
3. Voltmeter (between generator (B) terminal and ground)
4. Battery
5. Load
6. Switch
NOTE:
Turn off switches of all accessories (wiper, heater etc.).
NOTE:
Consideration should be taken that voltage will differ
somewhat with regulator case temperature as shown in
the graph.

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2) Ground F terminal and start engine, then measure voltage at
B terminal as shown in left figure.
Voltage is higher than standard value
It is considered that generator itself is good but IC regulator
has been damaged, replace IC regulator.
Voltage is lower than standard value
Generator itself has problem, check the generator.
Load Check
1) Run engine at 2,000 rpm and turn on head light and heater
motor.
2) Measure current and if it is less than 20 A repair or replace
generator.
OVERCHARGED BATTERY
1) To determine battery condition, refer to Battery section.
2) If obvious overcharged condition exists as evidenced by
excessive spewing of electrolyte, measure generator B ter-
minal voltage at engine 2,000 rpm.
3) If measured voltage is higher than upper limit value, proceed
to disassembly section of generator service.
4) Check ground of brushes. If brushes are not grounded,
replace IC regulator. Then check field coil for grounds and
shorts, referring to “INSPECTION” section.
On-Vehicle Service
Battery
Jump starting in case of emergency
WITH AUXILIARY (BOOSTER) BATTERY
Both booster and discharged battery should be treated carefully
when using jumper cables. Follow procedure outlined below,
being careful not to cause sparks.
CAUTION:
If vehicle is manual transmission model and has a cata-
lytic converter, do not push or tow it to start. Damage to
its emission system and/or to other parts may result.

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1) Set parking brake and place automatic transmission in
PARK (NEUTRAL on manual transmission). Turn off ignition,
turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line, add dis-
tilled water.
3) Attach end of one jumper cable to positive terminal of
booster battery and the other end of the same cable to posi-
tive terminal of discharged battery. (Use 12-volt battery only
to jump start engine).
4) Attach one end of the remaining negative cable to negative
terminal of booster battery, and the other end to a solid
engine ground (such as exhaust manifold) at least 45 cm (18
in.) away from battery of vehicle being started.
5) Start engine of vehicle with booster battery and turn off elec-
trical accessories. Then start engine of the vehicle with dis-
charged battery.
6) Disconnect jumper cables in the exact reverse order.
WITH CHARGING EQUIPMENT
WARNING:
Departure from these conditions or procedure
described below could result in:
–Serious personal injury (particularly to eyes) or
property damage from such causes as battery explo-
sion, battery acid, or electrical burns.
–Damage to electronic components of either vehicle.
Remove rings, watches, and other jewelry. Wear
approved eye protection.
Be careful so that metal tools or jumper cables do not
contact positive battery terminal (or metal in contact
with it) and any other metal on vehicle, because a short
circuit could occur.
WARNING:
Do not connect negative cable directly to negative termi-
nal of dead battery.
CAUTION:
When jump starting engine with charging equipment, be
sure equipment used is 12-volt and negative ground. Do
not use 24-volt charging equipment. Using such equip-
ment can cause serious damage to electrical system or
electronic parts.

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Dismounting
1) Disconnect negative cable (3).
2) Disconnect positive cable (2).
3) Remove retainer (5).
4) Remove battery (1).

Handling
When handling battery, following safety precautions should be
followed:
Hydrogen gas is produced by battery. A flame or spark near
battery may cause the gas to ignite.
Battery fluid is highly acidic. Avoid spilling on clothing or
other fabric. Any spilled electrolyte should be flushed with
large quantity of water and cleaned immediately.
Remounting
1) Reverse removal procedure.
2) Torque battery cables to specification.
Tightening torque
Body ground bolt (a) : 8.0 N·m (0.8 kg-m, 6.0 lb-ft)
Generator
Generator belt
Refer to “Water Pump Belt and Cooling Fan” in Section 6B.
4. Body ground bolt
NOTE:
Check to be sure that ground cable has enough clear-
ance to hood panel by terminal.

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Unit Repair Overhaul
Generator
Dismounting
1) Disconnect negative (–) cable (2) at battery (1).
2) Remove bolts (2) and then canister (1) together with its
bracket.
3) Disconnect “B” terminal wire (3) and coupler (2) from gener-
ator (1).
4) Remove generator belt. Refer to “Water Pump Belt and
Cooling Fan” in Section 6B.
5) Remove generator.
1. Generator adjusting bolt
2. Generator pivot bolt
3.“B” terminal

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Remounting
1) Mount generator on the generator bracket.
2) Tighten generator bolts.
Tightening torque
Generator pivot bolt
(a) : 23 N·m (2.3 kg-m, 16.5 lb-ft)
(b) : 50 N·m (5.0 kg-m, 36.0 lb-ft)
3) Install generator (cooling fan) belt. Refer to “Water Pump
Belt and Cooling Fan” in Section 6B.
4) Connect “B” terminal wire (3) and coupler to generator.
Tightening torque
“B” terminal outer nut of generator
(b) : 8.0 N·m (0.8 kg-m, 6.0 lb-ft)
5) Install canister.
6) Connect negative (–) cable at battery.
Disassembly and reassembly
1. Upper generator bolt (Short)
2. Lower generator bolt (Long)
1. Pulley 5. Rotor 9. Rear housing
2. Front housing 6. Stator 10. Brush
3. Bearing 7. IC regulator
4. Retainer 8. Rectifier