Get Charging System -> Unit Repair Overhaul Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

6H-14 CHARGING SYSTEM

UNIT REPAIR OVERHAUL

GENERATOR

1. Pulley nut

2. Pulley

3. Drive end frame

4. Stator

5. Stud bolt

6. Drive end bearing

7. Bearing retainer

8. Rotor

9. Bearing cover

10. End housing bearing

11. Bearing cover

12. Washer

13. Rear end frame

14. Rectifier

15. Insulator

16. Regulator

17. Brush

18. Brush holder

19. Rear end cover

20. Retainer plate screw

21. Rear end frame nut

22. Rear end frame bolt

23. Rectifier holder screw

24. B terminal inner nut

25. IC regulator screw

26. Brush holder screw

27. Rear end cover screw

: Tightening Torque

DISASSEMBLY

1) Remove B terminal inner nut (1) and insulator (2).

2) Remove 3 screws (3) and remove rear end cover (4).

3) Remove 2 screws (1) and pull out brush holder assembly (2).

4) Remove 3 screws (3) and IC regulator (4).

5) Remove brush holder cover from brush holder.

6) Remove rectifier holder screws (1).

7) Remove rectifier holder (2).

8) Hold shaft by using hexagonal box wrench and remove pulley

nut (1), and then pull out pulley (2).

CAUTION:

D To hold shaft, use hexagonal box. Duodecimal box

may cause slipping and consequential shaft or

tool damage.

D Do not attempt to hold pulley by using vise or pipe

wrench so as not to distort it.

9) Remove rear end frame nuts (3) and bolts (4).

10) Drive out rear end frame (1) with rotor tapping shaft (2) lightly

by using plastic hammer.

11) Separate rear end frame from rotor evenly by using plastic

hammer.

CAUTION:

Do not hit shaft at slip ring side, when separating ro-

tor and rear end frame.

CHARGING SYSTEM 6H-15

12) If required, use bearing puller (2) to remove end housing bear-

ing (1) and bearing cover (3).

CAUTION:

Care must be exercised so as not to distort cooling

fan blade while applying puller.

13) If required, remove 4 screws, retainer plate (1) and then drive

out drive end bearing (2).

14) If required, remove stud bolts and then pull out stator.

NOTE:

Heating drive end frame may facilitate removal of stator.

6H-16 CHARGING SYSTEM

INSPECTION

Rotor

Open Circuit

Using ohmmeter, check for continuity between slip rings of rotor

(1). If there is no continuity, replace rotor.

Standard resistance: About 2.9 W

Ground

Using ohmmeter, check that there is no continuity between slip ring

and rotor (1). If there is continuity, replace rotor.

Slip Rings

D Check slip rings for roughness or scoring. If rough or scored, re-

place rotor.

D Using a vernier caliper, measure slip ring diameter.

Standard diameter: 14.4 mm (0.567 in.)

Minimum diameter: 12.8 mm (0.504 in.)

If the diameter is less than minimum, replace the rotor.

Stator

Open Circuit

Using ohmmeter, check all leads for continuity. If there is no conti-

nuity, replace stator.

Ground

Using ohmmeter, check that there is no continuity between coil

leads and stator core. If there is continuity, replace stator.

CHARGING SYSTEM 6H-17

Brush

Exposed Brush Length

Check each brush for wear by measuring its length as shown. If

brush is found worn down to service limit, replace brush. Refer to

“Replace Brush” in this section.

Exposed brush length “a”

Standard : 10.5 mm (0.413 in.)

Limit : 1.5 mm (0.059 in.)

Rectifier

Positive Rectifier

1) Using an ohmmeter, connect one tester probe to the B terminal

(1) and the other to each rectifier terminal (2).

2) Reverse the polarity of tester probes and repeat step 1).

3) Check that one shows continuity and the other shows no conti-

nuity.

If there is continuity, replace rectifier holder.

Negative Rectifier

1) Using ohmmeter, connect one tester probe to each negative ter-

minal (1) and the other to each rectifier terminal (2).

2) Reverse the polarity of tester probes and repeat step 1).

3) Check that one shows continuity and the other shows no conti-

nuity.

If there is continuity, replace rectifier holder.

6H-18 CHARGING SYSTEM

Bearing

Drive End Bearing

Check that bearing is not rough or worn.

End Housing Bearing

Check that bearing is not rough or worn.

When removal is necessary, refer to disassembly of UNIT REPAIR

OVERHAUL.

REPLACE BRUSH

1) Unsolder and remove brush and spring.

2) Run wire of new brush through the hole in the brush holder, and

insert spring and brush into brush holder.

3) Solder brush wire to brush holder at specified exposed length.

Exposed length “a”: 10.5 mm (0.413 in.)

4) Check that brush moves smoothly in brush holder.

5) Cut off excess wire.

6) Apply insulation paint to the soldered area.

CHARGING SYSTEM 6H-19

ASSEMBLY

1) If end housing bearing (1) is removed, install it.

2) Check end housing bearing turns smoothly.

3) If stator (2) is removed, install stator and tighten stud bolts (1).

4) If drive end bearing (3) is removed, install it.

5) Check drive end bearing turns smoothly.

Tightening Torque

(a): 8.8 N

m (0.88 kg-m, 6.5 lb-ft)

(b): 2.6 N

m (0.26 kg-m, 2.0 lb-ft)

6) Place space collar and drive end frame (2) on pulley, and then

install rotor (1) to drive end frame.

7) Install rear end frame to drive end frame.

8) Tighten bolts and nuts to specified torque.

Tightening Torque

(a): 4.5 N

m (0.45 kg-m, 3.5 lb-ft)

9) Install pulley (1) and tighten pulley nut (2) with holding shaft us-

ing hexagonal box wrench to specified torque.

Tightening Torque

(a): 113 N

m (11.3 kg-m, 81.5 lb-ft)

6H-20 CHARGING SYSTEM

10) Install rectifier holder (1). Curl stator leads (2) as shown in fig-

ure.

CAUTION:

When installing rectifier, check to confirm that stator

leads have enough clearance with cooling fan

blades.

Tightening Torque

(a): 2.0 N

m (0.2 kg-m, 1.5 lb-ft)

11) Install brush holder cover to brush holder.

12) Place IC regulator (1) together with brush holder (2) horizon-

tally on rear end frame (3).

13) Install 5 screws.

Tightening Torque

(a): 2.0 N

m (0.2 kg-m, 1.5 lb-ft)

14) Install rear end cover (1).

Tightening Torque

(a): 3.7 N

m (0.37 kg-m, 3.0 lb-ft)

15) Install insulator (2) and tighten B terminal inner nut (3) to speci-

fied torque.

Tightening Torque

(b): 3.6 N

m (0.36 kg-m, 3.0 lb-ft)

16) Make sure that rotor turns smoothly.

CHARGING SYSTEM 6H-21

Charging System -> Unit Repair Overhaul for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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