charging SUZUKI JIMNY 2005 3.G Service Owner's Guide

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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

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Inspection
Rotor
1) Using ohmmeter, check for continuity between slip rings of
rotor (1). If there is no continuity, replace rotor.
Standard resistance between slip rings of rotor
1.8 – 2.1
Ω
ΩΩ Ω
2) Using ohmmeter, check that there is no continuity between
slip ring and rotor core. If there is continuity, replace rotor.
3) Check slip rings for roughness or scoring. If rough or scored,
replace rotor (1).
4) Check slip rings for roughness or scoring. If rough or scored,
replace rotor.
Using a vernier caliper, measure the slip ring diameter.
If the diameter is less than minimum, replace the rotor.
Slip ring diameter
Standard : 14.4 mm (0.567 in.)
Limit : 14.0 mm (0.551 in.)
Stator
1) Using ohmmeter, check all leads for continuity.
If there is no continuity, replace stator (1).

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2) Using ohmmeter, check that there is no continuity between
coil leads (2) and stator core. If there is continuity, replace
stator (1).
Brush and Brush Holder
Check each brush for wear by measuring its length.
If brush is found worn down to service limit, replace brush.
Brush length “a”
Standard : 16 mm (0.63 in.)
Service limit : 2 mm (0.08 in.)
Rectifier
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 rectifier (1).

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Drive End Bearing
Check that the bearing is not rough or worn.
End Housing Bearing
Check that the bearing is not rough or worn.
When removal is necessary, use bearing puller to remove end
housing bearing (1).
Replace Brush
1) Unsolder and remove the brush and spring.
2) Run the wire of a new brush through the spring and the hole
in the brush holder, and insert the spring and brush into the
brush holder.
3) Solder the brush wire to the brush holder at specified
exposed length.
Exposed brush length
“a” : 10.5 mm (0.413 in.)
4) Check that the brush moves smoothly in the brush holder.
5) Cut off the excess wire.
6) Apply insulation paint to the soldered area.
CAUTION:
Be careful not to distort cooling fan blade while applying
puller.

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Specifications
Battery
55B24R TYPE

38B20R TYPE
Generator
Tightening Torque Specification
Rated capacity 36 AH/5HR, 12 Volts
Electrolyte 3.1 L (6.55/5.46 US/lmp pt)
Electrolyte S.G. 1.28 when fully charged at 20 °C (68 °F)
Rated capacity 28 AH/5HR, 12 Volts
Electrolyte 2.1 L (4.44/3.70 US/lmp pt)
Electrolyte S.G. 1.28 when fully charged at 20 °C (68 °F)
Type 70 A type
Rated voltage 12 V
Nominal output 70 A
Permissible max. speed 18,000 r/min.
No-load speed 1,300 r/min (rpm)
Setting voltage 14.4 to 15.0 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 23 2.3 16.5
“B” terminal inner nut 4.2 0.42 3.0
“B” terminal outer nut 8 0.8 6.0
Pulley nut 118 11.8 85.5
Rear end frame nuts
4.50.453.5
Rear end cover nuts
Rectifier “B” bolt 3.9 0.39 3.0
Stator stud bolts 8.8 0.88 6.5
Drive end bearing plate screws 2.6 0.26 2.0
Rectifier screws
2.00.201.5
Regulator and brush holder screws
Terminal plate bolt 3.8 0.38 3.0

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