Get Charging System -> On-Vehicle Service Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

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.

1) Set parking brake and place manual transmission in NEUTRAL.

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 en-

gine).

4) Attach one end of the remaining negative cable to negative ter-

minal 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.

6) Disconnect jumper cables in the exact reverse order.

WARNING:

D Departure from these conditions or procedure de-

scribed below could result in:

1) Serious personal injury (particularly to eyes) or

property damage from such causes as battery ex-

plosion, battery acid, or electrical burns.

2) Damage to electronic components of either vehicle.

D Remove rings, watches, and other jewelry. Wear ap-

proved eye protection.

D 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 ter-

minal of dead battery.

6H-10 CHARGING SYSTEM

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 equip-

ment can cause serious damage to electrical system or

electronic parts.

REMOVAL

1) Open engine hood.

2) Disconnect negative cable (1).

3) Disconnect positive cable (2).

4) Remove retainer (3).

5) Remove battery (4).

HANDLING

When handling battery, following safety precautions should be fol-

lowed:

D Hydrogen gas is produced by battery. A flame or spark near bat-

tery may cause the gas to ignite.

D Battery fluid is highly acidic. Avoid spilling on clothing or other

fabric. Any spilled electrolyte should be flushed with large quan-

tity of water and cleaned immediately.

INSTALLATION

1) Reverse removal procedure.

2) Torque battery cables.

NOTE:

D Check to be sure that ground cable has enough clear-

ance to hood panel by terminal.

D Body and battery cable should not interfere with each

other.

D After tightening positive terminal, be sure to put cap

onto it securely.

CHARGING SYSTEM 6H-11

GENERATOR

1. Adjusting bolt

2. Generator

3. Pivot bolt

4. “B” terminal wire

5. Coupler

6. Nut

: Tightening Torque

REMOVAL

1) Disconnect negative cable (1) at battery (2).

2) Remove front bumper.

3) Disconnect “B” terminal wire (3) and coupler (4) from generator

(5).

4) Remove adjusting bolt (1) and pivot bolts (2).

5) Remove generator.

INSTALLATION

Reverse above procedure giving specified tension to drive belt.

Refer to “Generator (Water Pump) Belt” for belt tension.

Tightening Torque

(a): 22 N·m (2.2 kg-m, 16.0 lb-ft)

(b): 50 N·m (5.0 kg-m, 36.5 lb-ft)

(c): 7 N·m (0.7 kg-m, 5.0 lb-ft)

6H-12 CHARGING SYSTEM

GENERATOR (WATER PUMP) BELT

BELT TENSION INSPECTION

1) Inspect belt cracks, cuts, deformation, wear and cleanliness.

2) Check belt for tension. Belt is in proper tension when it deflects

12 to 15 mm (0.47 – 0.59 in.) under thumb pressure (1) (about

10 kg or 22 lb.).

Belt tension “a” : 6 – 7 mm (0.24 – 0.28 in.) as deflection

NOTE:

When replacing belt with a new one, adjust belt tension to

5 – 6 mm (0.20 – 0.24 in.).

3) If belt is too tight or too loose, loosen adjusting bolt (2) and pivot

bolts (3) and adjust it to proper tension by displacing generator

(4) position.

4) Tighten generator adjusting bolt and pivot bolts.

Tightening Torque

(a): 22 N·m (2.2 kg-m, 16.0 lb-ft)

(b): 50 N·m (5.0 kg-m, 36.5 lb-ft)

5) Connect negative cable at battery terminal.

REMOVAL

1) Disconnect negative cable at battery.

2) Remove front bumper.

3) Loosen generator adjusting bolt (1) and generator pivot bolts

(2).

4) Slacken belt (3) by displacing generator and then remove it.

INSTALLATION

1) Install belt to water pump pulley, crankshaft pulley and genera-

tor pulley.

2) Adjust belt tension.

3) Tighten water pump belt adjusting bolt and pivot bolts.

4) Connect negative cable at battery.

CHARGING SYSTEM 6H-13

Charging System -> On-Vehicle Service for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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