bolts SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-7
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.

Downloaded from www.Manualslib.com manuals search engine 6H-12 CHARGING SYSTEM
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

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-13
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

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-17
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

Downloaded from www.Manualslib.com manuals search engine EXHAUST SYSTEM 6K-1
6F1
6F2
6G
6H
7D
7E
7F
7D
7E
7F
8A
8B
8C
8D
8E
9
7A1
6K
7C1
SECTION 6K
EXHAUST SYSTEM
CONTENTS
General Description ........................................6K-1
Maintenance ....................................................6K-1On-Vehicle Service ......................................... 6K-2
Exhaust Manifold .......................................... 6K-2
Exhaust Pipe ................................................. 6K-2

General Description
The exhaust system of this vehicle consists of the exhaust manifold, exhaust center pipe, muffler, seals, etc.
The catalytic converter is an emission control device added to the exhaust system to lower the level of Hydro-
carbon (HC), Carbon Monoxide (CO) and Oxides of Nitrogen (NOx) pollutants in the exhaust gas. The catalyst
in the catalytic converter is of “Three way” type.
Maintenance
At every interval of periodic maintenance service, and when vehicle is raised for other service, check exhaust
system as follows:
Check rubber mountings for damage, deterioration and out of position.
Check exhaust system for leakage, loose connection, dent and damage.
If bolts or nuts are loosened, tighten them to specified torque. Refer to “Components” in this section.
Check nearby body areas for damaged, missing, or mispositioned part, open seam, hole, loose connection
or any other defect which could permit exhaust fumes to seep into vehicle.
Make sure that exhaust system components have enough clearance from underbody to avoid overheating
and possible damage to passenger compartment carpet.
Any defect should be fixed at once. NOTE:
Whether following parts are used in the particular vehicle or not depends on specification. Be sure to
bear this in mind when performing service work.
Three-Way Catalytic Converter (TWC)
CAUTION:
Be sure to use UNLEADED FUEL for the catalytic converter equipped vehicle. Use of LEADED FUEL
will affect performance of the catalytic converter adversely to a great extent.
WARNING:
To avoid danger of being burned, do not touch exhaust system when system is hot.
Any service on exhaust system should be performed when system is cool.

Downloaded from www.Manualslib.com manuals search engine 6K-2 EXHAUST SYSTEM
On-Vehicle Service
COMPONENTS
Exhaust Manifold
REMOVAL AND INSTALLATION
Refer to “Exhaust Manifold” in Section 6A1 for removal and installation procedures of exhaust manifold.
INSPECTION
Check seals for deterioration or damage.
Exhaust Pipe
REMOVAL AND INSTALLATION
For replacement of exhaust pipe, exhaust center pipe, muffler or any parts used to mount or connect them, be
sure to hoist vehicle and observe WARNING under “Maintenance” and the following.
1. Exhaust pipe (Vehicle without TWC) 6. Gasket 11. Mounting nuts
2. Exhaust pipe (Vehicle with TWC) 7. Spring Tightening torque
3. Exhaust center pipe 8. Mounting Do not reuse.
4. Muffler 9. Oxygen sensor
5. Seal ring 10. Mounting bolts
CAUTION:
Exhaust pipe with three way catalytic converter should not be exposed to any impulse. Do not drop it
or hit it against something.