ignition SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine CRANKING SYSTEM 6G-3
Condition Possible Cause Correction
Motor not running
(No operating sound of
magnetic switch)Shift lever switch is not in P or N, or not adjusted
(A/T)Shift in P or N, or adjust switch.
Battery run down Recharge battery.
Battery voltage too low due to battery deteriora-
tionReplace battery.
Poor contact in battery terminal connection Retighten or replace.
Loose grounding cable connection Retighten.
Fuse set loose or blown off Tighten or replace.
Poor contacting action of ignition switch and mag-
netic switchReplace.
Lead wire coupler loose in place Retighten.
Open-circuit between ignition switch and magnetic
switchRepair.
Open-circuit in pull-in coil Replace magnetic switch.
Brushes are seating poorly or worn down Repair or replace.
Poor sliding of plunger and/or pinion Repair.
Motor not running
(Operating sound of
magnetic switch
heard)Battery run down Recharge battery.
Battery voltage too low due to battery deteriora-
tionReplace battery.
Loose battery cable connections Retighten.
Burnt main contact point, or poor contacting action
of magnetic switchReplace magnetic switch.
Brushes are seating poorly or worn down Repair or replace.
Weakened brush spring Replace.
Burnt commutator Replace armature.
Layer short-circuit of armature Replace.
Crankshaft rotation obstructed Repair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfac-
tory, inspect starting
motor)Insufficient contact of magnetic switch main con-
tactsReplace magnetic switch.
Layer short-circuit of armature Replace.
Disconnected, burnt or worn commutator Repair commutator or replace
armature.
Worn brushes Replace brush.
Weakened brush springs Replace spring.
Burnt or abnormally worn end bush Replace bush.
Starting motor run-
ning, but not cranking
engineWorn pinion tip Replace over-running clutch.
Poor sliding of over-running clutch Repair.
Over-running clutch slipping Replace over-running clutch.
Worn teeth of ring gear Replace flywheel (M/T) or drive
plate (A/T).
Noise
Abnormally worn bush Replace bush.
Worn pinion or worn teeth of ring gear Replace pinion or flywheel
(M/T) or drive plate (A/T).
Poor sliding of pinion (failure in return movement) Repair or replace.
Worn internal or planetary gear teeth Replace.
Lack of oil in each part Lubricate.

Downloaded from www.Manualslib.com manuals search engine 6G-4 CRANKING SYSTEM
Performance Test
PULL-IN TEST
Connect battery to magnetic switch as shown.
Check that plunger and pinion move outward.
If plunger and pinion don’t move, replace magnetic switch.
HOLD-IN TEST
While connected as above with plunger out, disconnect negative
lead from terminal “M”.
Check that plunger and pinion remain out.
If plunger and pinion return inward, replace magnetic switch.
PLUNGER AND PINION RETURN TEST
Disconnect negative lead from starting motor body.
Check that plunger and pinion return inward.
If plunger and pinion don’t return, replace magnetic switch. Starting motor does
not stop runningFused contact points of magnetic switch Replace magnetic switch.
Short-circuit between turns of magnetic switch coil
(layer short-circuit)Replace magnetic switch.
Failure of returning action in ignition switch Replace.
CAUTION:
Each test must be performed within 3 – 5 seconds to
avoid coil from burning.
NOTE:
Before testing, disconnect lead wire from terminal M.
1. Terminal “S”
2. Terminal “M”
3. Lead wire (switch to motor)
Condition Possible Cause Correction

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-1
6F1
6F2
6G
6K
7D
7E
7F
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
7A
6H
7B1
10B
SECTION 6H
CHARGING SYSTEM
CONTENTS
General Description ....................................... 6H-2
Battery .......................................................... 6H-2
Generator ..................................................... 6H-4
Diagnosis ........................................................ 6H-6
Battery .......................................................... 6H-6
Generator ..................................................... 6H-7
On-Vehicle Service......................................... 6H-9
Battery .......................................................... 6H-9
Jump starting in case of emergency......... 6H-9
Dismounting ........................................... 6H-11
Handling ................................................. 6H-11
Remounting ............................................ 6H-11Generator ................................................... 6H-11
Generator belt ........................................ 6H-11
Unit Repair Overhaul ................................... 6H-12
Generator ................................................... 6H-12
Dismounting ........................................... 6H-12
Remounting ............................................ 6H-13
Disassembly and reassembly ................ 6H-13
Inspection ............................................... 6H-14
Specifications............................................... 6H-17
Battery........................................................ 6H-17
Generator ................................................... 6H-17
Tightening Torque Specification ................ 6H-17

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 air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation 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).

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-5
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
1. Pulley 5. Stator core 9. Front housing IG: Ignition terminal
2. Pulley nut 6. Field coil 10. Rear housing L: Lamp terminal
3. Rotor fan 7. Regulator B: Generator output (Battery terminal)
4. Stator coil 8. Brush E: Ground

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-8 CHARGING SYSTEM
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.

Downloaded from www.Manualslib.com manuals search engine 6H-10 CHARGING SYSTEM
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.