charging system SUZUKI SWIFT 2004 2.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine 1J-6 Charging System:
Generator Test (Overcharged Battery Check)S7RS0B1A04004
1) To determine battery condition, refer to “Battery Description”.
2) If obvious overcharge condition exists as evidenced by excessive spewing of electrolyte, measure
generator “B” terminal voltage at engine 2000 rpm. 3) If measured voltage is higher than upper limit value,
proceed to disassemble generator.
4) Check ground of brushes. If brushes are not grounded, replace IC regulator. Then check field coil
for grounds and shorts, referring to “Generator
Inspection”.
Repair Instructions
Jump Starting in Case of EmergencyS7RS0B1A06001
CAUTION!
If vehicle is manual transaxle model and has
a catalytic converter, do not push or tow it to
start. Damage to its emission system and/or
to other parts may result.

Both booster and discharged battery should be treated
carefully when using ju mper cables. Follow the
procedure outlined as follows, being careful not to cause
sparks.
WARNING!
• Departure from these conditions or procedure described as follows could
result in:
– Serious personal injury (particularly to eyes) or property damage from such
causes as battery explosion, 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. • Never expose battery to open flame or
electric spark. Batteries generate gas
which is flammable and explosive.
• Do not allow battery fluid to contact eyes, skin, fabrics, or painted surface as fluid is
a corrosive acid. Flush any contacted area
with water immediately and thoroughly.
• Batteries should always be kept out of reach of children.
• Do not connect negative cable directly to negative terminal of dead battery.

1) Set parking brake and place automatic transaxle in PARK (NEUTRAL on manual transaxle). Turn off
ignition, turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line, add distilled water.
3) Attach end of one jumper cable to positive terminal of booster battery and the other end of the same
cable to positive 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 electrical accessories. Then start engine of the
vehicle with discharged battery.
16.0
15.5
15.0
14.5
14.0
13.5
13.0 -30 0 20
[C]
[D]
68
22120 (˚C)
248 (˚F)
(V)
I6RS0C1A0001-02

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With Charging Equipment
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 equipment
can cause serious damage to electrical
system or electronic parts.

Battery Dismounting and RemountingS7RS0B1A06002
WARNING!
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.

Dismounting
1) Disconnect negative cable (1).
2) Disconnect positive cable (2).
3) Remove retainer (3).
4) Remove battery (4).
Remounting 1) Reverse removal procedure.
2) Tighten battery cables securely.
Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S7RS0B1A06003
WARNING!
Disconnect negative cable at battery before
checking and adjusting belt tension.

1) Inspect belt for cranks, cuts, deformation, wear and clealiness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when it deflects the following specification under thumb
pressure (about 10 kg or 22 lb.).
If belt tension is out of spec ification, go to next steps.
Water pump / generator drive belt tension
“a”
Existing belt: 4.5 – 5.5 mm (0.18 – 0.22 in.) as
deflection / 10 kg (22 lbs)
New belt: 3.5 – 4 mm (0.14 – 0.16 in.)as deflection
/ 10 kg (22 lbs)
5. Body ground bolt
1
3 5
2
4
I4RS0B1A0006-01
“a”
I5JB0A1A0008-01

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3) After loosening generator bracket bolts (2) and pivot bolt (3), adjust belt tensio n to specification described
at step 2) by loosening / tightening generator adjust
bolt (1).
4) Tighten generator bracket bolts and pivot bolt as specified torque.
Tightening torque
Generator bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
Generator pivot bolt (b): 50 N·m (5.0 kgf-m, 36.0
lb-ft)
5) Check belt tension for specification after turning crankshaft two rotations clockwise.
6) Tighten generator adjusting bolt (1) as specified torque.
Tightening torque
Generator adjusting bolt (c): 7 N·m (0.7 kgf-m,
5.0 lb-ft) by the specified procedure.
7) Connect negative cable at battery.Water Pump / Generator Drive Belt Removal and
Installation
S7RS0B1A06004
Removal 1) Disconnect negative cable at battery.
2) If vehicle equipped with A/C, remove compressor drive belt before removing water pump belt (1). Refer
to “Compressor Drive Belt Removal and Installation
in Section 7B” or “Compr essor Drive Belt Removal
and Installation in Section 7B”.
3) Loosen drive belt adjusting bolt (2) and generator pivot bolt (3).
4) Loosen generator adjusting bolt (4), and then remove water pump belt.
Installation
Reverse removal procedure for installation noting the
following.
• Adjust belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment” and “Compressor Drive Belt Inspection
and Adjustment in Section 7B” or “Compressor Drive
Belt Inspection and Adjustment in Section 7B”.
1, (c)
2, (a)
3, (b)
I5RW0C160007-01
4
23
1
I6RS0C1A0002-01

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Generator Unit ComponentsS7RS0B1A06005
Generator Dismounting and RemountingS7RS0B1A06006
Dismounting1) Disconnect negative (–) cable at battery.
2) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in
Section 3A”.
3) Disconnect generator lead wire (“B” terminal wire) and coupler from generator.
4) Remove generator belt. Refer to “Water Pump / Generator Drive Belt Re moval and Installation”.
5) Remove generator bracket bolts and generator pivot bolt.
6) Remove generator. Remounting
Reverse dismounting procedure for remounting noting
the followings.
• Tighten each bolt and nut to specified torque referring
to “Generator Unit Components”.
• Adjust belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment”.
(a)
(b)
(c)
1
2 8
3 7 5 49 6(c)
(c)
I6RS0C1A0003-02
1. “B” terminal nut
5. Generator pivot bolt : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft)
2. “B” terminal wire 6. Generator belt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft)
3. Connector 7. Generator : 25 N⋅m (2.5 kgf-m, 18.5 lb-ft)
4. Generator adjusting bolt 8. Generator bracket bolt

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Generator ComponentsS7RS0B1A06007
1211
13
14
(a)(b)
(c)
(d)
1 2
3 4
56
7
89
10 15
16
I4RS0B1A0007-01
1. Pulley nut 6. Drive end bearing 11. Rear housing 16. “B” terminal nut
2. Pulley 7. Bearing retainer 12. Rectifier : 118 N⋅m (11.8 kgf-m, 85.5 lb-ft)
3. Front housing 8. Rotor 13. Regulator : 4.5 N⋅m (0.45 kgf-m, 3.5 lb-ft)
4. Stator 9. Rear end bearing 14. Brush : 3.5 N⋅m (0.35 kgf-m, 2.5 lb-ft)
5. Frame bolt 10. Retainer screw 15. “B” terminal : 8.0 N⋅m (0.8 kgf-m, 6.0 lb-ft)

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Generator InspectionS7RS0B1A06008
Rotor
• Using ohmmeter, connect positive terminal to “FR” terminal and connect negative terminal to “B” terminal of generator, check that continuity between “B” terminal and “FR” terminal. If there is no continuity, replace rotor or
regulator.
• Using an ohmmeter (1), check for continuity between slip ring s (2) of rotor. If there is no continuity, replace the rotor.
Standard resistance between slip rings of rotor
: 1.7 – 2.0 Ω
I5JB0A1A0012-01
I4RS0B1A0005-01

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• Using an ohmmeter (1), check that there is no continuity between slip ring (2) and rotor core (3). If there is
continuity, replace the rotor.
• Check slip rings for roughness or scoring. If rough or scored, replace the rotor.
Stator
• Using an ohmmeter (1), check all leads (2) for continuity. If there is no co ntinuity, replace the stator.
• Using an ohmmeter (1), check that there is no continuity between coil leads (2) and stator core (3). If
there is continuity, replace the stator. Brush and Brush Holder
Check each brush (1) for wear by measuring its length
as shown. If brush is found worn down to service limit,
replace brush.
Exposed brush length “a”
Standard: 16 mm (0.63 in.)
: Limit: 5.0 mm (0.20 in.)
Rectifier
Using ohmmeter, check continuity between “B” terminal
(1) or “E” terminal (2) and each diode lead (3).
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
(4).
I4RS0B1A0008-01
I4RS0B1A0009-01
I4RS0B1A0010-01
I4RS0B1A0011-01
1
1
3 3
2
2
4
I6RS0B1A1010-01

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Specifications
Charging System SpecificationsS7RS0B1A07001
Battery
Battery
: 48AH/20H, 40.6AH/5H 12 V
Generator
Tightening Torque SpecificationsS7RS0B1A07002
NOTE
The specified tightening torque is also described in the following.
“Generator Unit Components”
“Generator Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Nominal output
12 V
Rated capacity 48 Ah/20 h
40.6 Ah/5 h
Cold cranking amperes 300 A (DIN)
Ty p e 80A type
Rated voltage 12 V
Nominal output 80A
Permissible max. speed 18,000 r/min.
No-load speed 1200 r/min. (rpm)
Regulated voltage 14.2 – 14.8 V at 25 ° C (77 °F)
Exposed brush length Standard: 16 mm (0.63 in.)
Limit: 5.0 mm (0.02 in.)
Permissible ambient temperature –30 to 100 °C (–22 to 212 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Fastening partTightening torque
Note
N ⋅mkgf-mlb-ft
Generator bracket bolt 25 2.5 18.0 )
Generator pivot bolt 50 5.0 36.0 )
Generator adjusting bolt 70.7 5.0by the specified
procedure.
)

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10) Check pedal height and play referring to “Brake Pedal Free Height Inspection” and “Brake Pedal
Play Inspection”.
11) Check each installed part for fluid leakage and perform brake test.
12) Evacuate and charge refrigerant by referring to “Evacuating of A/C Syst em” and “Procedure of
Charging” under “Operation Procedure for
Refrigerant Charge in Section 7B” or “Operation
Procedure for Refrigerant Charge in Section 7B”.
Brake Booster Inspection and AdjustmentS7RS0B4106018
Installation Position of Push Rod
If push rod clevis (1) has b een removed, adjust distance
between booster installation surface (without including
packing) and the center of clevis pin hole to standard
value “a” and tighten nut (a) to specified torque. Distance “a” between center of booster clevis pin
hole and booster surface
Standard:
114.5 – 115.5 mm (4.51 – 4.54 in.)
Tightening torque
Clevis lock nut (a): 15 N·m (1.5 kgf-m, 11.0 lb-ft)
Specifications
Tightening Torque SpecificationsS7RS0B4107001
NOTE
The specified tightening torque is also described in the following.
“Front Brake Hose / Pipe Construction”
“Rear Brake Hose / Pipe Construction”
“Brake Pedal Components”
“Master Cylinder Components”
“Brake Booster Components”

Reference:
For the tightening torque of fastener not specified in this
section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B4108001
NOTE
Required service material is also described in the following.
“Master Cylinder Components”

I4RS0A410022-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Master cylinder fixing nut 15 1.5 11.0 )
Brake pipe flare nut for M10 16 1.6 11.5 )
Brake pipe flare nut for M12 19 1.9 14.0 )
Reservoir bolt 2.5 0.25 2.0 )
Booster mounting nut 13 1.3 9.5 )
Brake pedal bracket mounting bolt 13 1.3 9.5 )
Clevis lock nut 15 1.5 11.0 )

Downloaded from www.Manualslib.com manuals search engine 4E-21 ABS:
DTC C1057: Power Source CircuitS7RS0B4504014
Wiring Diagram
DTC Detecting Condition
The ABS control module monitors the power source voltage at terminal “E03-14”. When the power source voltage
becomes extremely high or low while vehicle is running at more than 20 km/h (13 MPH), this DTC will be set. As soon
as the power source volta ge becomes normal, the ABS warning light will be turned off and the ABS control module will
return to normal operation, bu t the set DTC will be remain.
DTC Troubleshooting
[A]: ABS hydraulic unit / control module connector (viewed from terminal side) 2. Main fuse box
1. Battery 3. ABS hydraulic unit / control module assembly
E03-14WHT/BLU
1 2
3
BLK
BLK
E03-13
E03-26
[A]
E03
15
16
17
18
19
20
21
22
23
24
25 2
3
4
5
6
7
8
9
10
11
12
1
13
14
26
12V
I6RS0C450011-01
Step
Action YesNo
1 Was “ABS Check” performed? Go to Step 2.Go to “ABS Check”.
2 1) Disconnect ABS hydraulic unit / control module connector with ignition switch turned OFF.
2) Check for proper connection to ABS hydraulic unit / control module connector at terminals “E03-14” and
“E03-13”.
3) If OK, then turn ignition switch to ON position and measure voltage between terminals “E03-14” and “E03-
13”.
Is voltage 9.7
± 0.3 V or more? Go to Step 5. Go to Step 3.
3 1) Turn ignition switch to OFF. 2) Check for proper connection to ABS hydraulic unit / control module connector at terminals “E03-13” and
“E03-26”.
3) If OK then turn ignition switch to ON and measure resistance between each terminal of “E03-13” and “E03-
26” and vehicle body ground.
Is resistance less than 2
Ω? Go to Step 4. “BLK” wire circuit in
open or high resistance.
4 1) Measure voltage between positive battery terminal and vehicle body ground with engine running.
Is voltage 9.7
± 0.3 V or more? Imperfect short between
“WHT/BLU” wire circuit
and body ground.
Check charging system
referring to “Generator
Test (Undercharged
Battery Check) in
Section 1J”.