Suzuki Grand Vitara JB416 / JB420. Manual - part 137

 

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Suzuki Grand Vitara JB416 / JB420. Manual - part 137

 

 

1J-6 Charging System: 

Repair Instructions

Jump Starting in Case of Emergency

S5JB0A1A06004

With Auxiliary (Booster) Battery

CAUTION

!

 

If vehicle is manual transmission 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 jumper 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:
a. Serious personal injury (particularly to 

eyes) or property damage from such 
causes as battery explosion, battery 
acid, or electrical burns.

b. Damage to electronic components of 

either vehicle.

• Never expose battery to open flame or 

electric spark. Batteries generate gas 
which is flammable and explosive.

• Remove rings, watches, and other jewelry. 

Wear approved eye protection.

• 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.

• 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.

• Batteries should always be kept out of 

reach of children.

 

1) Set parking brake and place automatic transmission 

in PARK (NEUTRAL on manual transmission).

2) Turn OFF ignition switch, turn OFF lights and all 

other electrical loads.

3) Check built-in indicator (if equipped). If it is clear or 

light yellow, replace the battery.

4) 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).

5) 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.

WARNING

!

 

Do not connect negative cable directly to 
negative terminal of dead battery.

 

6) Start engine of vehicle with booster battery and turn 

off electrical accessories. Then start engine of the 
vehicle with discharged battery.

7) Disconnect jumper cable in the exact reverse order.

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.

 

Charging System:  1J-7

Battery Dismounting and Remounting

S5JB0A1A06005

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.
2) Disconnect positive cable.
3) Remove retainer.
4) Remove battery.

Handling
When handling battery, the 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.

Remounting

1) Reverse removal procedure.
2) Tighten battery cables securely.

NOTE
Check to be sure that ground cable has 
enough clearance to hood panel by terminal.

 

Water Pump and Generator Drive Belt Removal 
and Installation (For M16 Engine)

S5JB0A1A06011

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 “P/S Pump and A/C Compressor (If 
Equipped) Drive Belt Removal and Installation for 
M16 Engine Model in Section 6C”
.

3) Loosen drive belt adjusting bolt (2) and generator 

pivot bolt (3).

4) Loosen water pump and generator drive belt 

adjuster bolt (4) to displace generator and then 
remove water pump belt.

Installation

1) Install belt (1) to water pump pulley (2), crankshaft 

pulley (3) and generator pulley (4).

2) Adjust belt tension by referring to “Water Pump and 

Generator Drive Belt Tension Inspection and 
Adjustment (For M16 Engine)”.

3) If vehicle equipped with A/C, install compressor drive 

belt referring to “P/S Pump and A/C Compressor (If 
Equipped) Drive Belt Removal and Installation for 
M16 Engine Model in Section 6C”
.

4) Connect negative cable at battery.

1. Battery

4. Body ground bolt

2. Positive cable

5. Retainer

3. Negative cable

6. Nut

3

6

5

2

4

1

I5JB0A1A0007-01

4

2

3

1

I5JB0A1A0001-01

4

2

1

3

I5JB0A1A0002-01

1J-8 Charging System: 

Water Pump and Generator Drive Belt Tension 
Inspection and Adjustment (For M16 Engine)

S5JB0A1A06012

WARNING

!

 

• Disconnect negative cable at battery 

before checking and adjusting belt 
tension.

• To help avoid danger of being burned, do 

not remove radiator cap while engine and 
radiator are still hot. Scalding fluid and 
steam can be blown out under pressure if 
cap is taken off too soon.

 

1) Inspect belt for cracks, cuts, deformation, wear and 

cleanliness. If it is necessary to replace belt, refer to 
“Water Pump and Generator Drive Belt Removal and 
Installation (For M16 Engine)”.

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.).

Water pump / generator drive belt tension “a”
Existing belt: 7.0 – 8.5 mm (0.28 – 0.33 in.) as 
deflection / 10 kg (22 lbs)
New belt: 5.5 – 6.5 mm (0.22 – 0.26 in.) as 
deflection / 10 kg (22 lbs)

NOTE
When replacing belt with a new one, adjust 
belt tension to 5.5 – 6.5 mm (0.22 – 0.26 in.).

 

3) If belt is too tight or too loose, adjust it to proper 

tension by displacing generator position.

4) To adjust belt tension, loosen generator adjusting 

bolt (3) and displace generator position by loosening 
on tightening adjuster bolt.

5) Tighten generator adjusting bolt (1) and pivot bolts 

(2) as specified torque.

Tightening torque
Generator adjusting bolt (a):  25 N·m (2.5 kgf-m, 
18.5 lb-ft)
Generator pivot bolt (b):  52.5 N·m (5.25 kgf-m, 
38.0 lb-ft)

6) Check belt for tension after turn crankshaft two 

rotations clockwise.

7) Tightening generator adjuster bolt (3) as specified 

torque.

Tightening torque
Generator adjuster bolt (c):  7.0 N·m (0.7 kgf-m, 
5.0 lb-ft)

8) Connect negative cable at battery.

“a”

I5JB0A1A0008-01

1, (a)

2, (b)

3, (C)

I5JB0A1A0009-01

Charging System:  1J-9

Water Pump and Generator Drive Belt On-Vehicle Inspection (For J20 Engine)

S5JB0A1A06013

[Type A]

1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of above conditions are found, replace belt, 

referring to “Water Pump and Generator Drive Belt Removal and Installation (For J20 Engine)”.

3) Make sure that tension indicator “A” is within the range “a”.

If indicator “A” comes into the NG range “c” passing “b”, replace generator belt with a new one.

NOTE
Use mirror when checking belt tension.

 

[Type B]
• Inspect belt for cracks, cuts, deformation, wear and cleanliness. If any of these conditions are found, replace belt, 

referring to “Water Pump and Generator Drive Belt Removal and Installation (For J20 Engine)”.

• Check to make sure that tension indicators are as follows in the figure by using mirror.

a. If the tension indicator “B” is found to the left of the indicator “A”, replace the generator belt.
b. If new generator belt has been installed, indicator “A” should be within “a” of the figure.

If it isn’t, it means that belt is not installed properly.
Reinstall it properly.

I1SQ01020003-01

I5JB0A1A0010-01

1. Water pump and generator drive belt

3. Water pump pulley

5. Tensioner

2. Crankshaft pulley

4. Tension pulley

6. Power steering pump pulley

 

 

 

 

 

 

 

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