Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 208

1J-22 Charging System: For Diesel Engine Model

Repair Instructions

Jump Starting in Case of Emergency

S6JB0A1A26001

With Auxiliary (Booster) Battery

CAUTION

!

 

If vehicle is manual transmission model and 
has a catalytic converter, do not push or tow 
vehicle to start. Damage to emission system 
and/or other parts of vehicle may result.

 

Both booster and discharged battery should be treated 
carefully when using jumper cables. Follow procedure 
outlined below, being careful not to cause sparks.

WARNING

!

 

• Departure from these conditions or 

procedure described below 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 electrolyte level. If it is below low level line, 

add distilled water.

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 that is providing jump start 

and turn off electrical accessories. Then Start engine 
of the vehicle with discharged battery.

7) Reverse connecting procedure exactly when 

disconnecting jumper cable. Negative cable must be 
disconnected from engine that was jump started first.

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 Remounting

S6JB0A1A26002

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.

 

Charging System: For Diesel Engine Model 1J-23

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) Torque battery cables to specification.

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

 

Tightening torque
Battery ground bolt (a):  12 N·m (1.2 kgf-m, 9.0 
lb-ft)

Generator Components

S6JB0A1A26004

1

2

(a)

3

4

I5JB0B1A0006-01

1

2

3

4

5

6

7

8

9

10

11

12

(a)

(c)

(d)

(b)

I5JB0B1A0007-01

1. Pulley

4. Bearing retainer

7. Coil assembly

10. Brush holder assembly

2. Drive end frame

5. Rotor assembly

8. Insulator

11. Rear end cover

3. Drive end bearing

6. Wave washer

9. Through bolt

12. Rear end cover nut

1J-24 Charging System: For Diesel Engine Model

Generator Dismounting and Remounting

S6JB0A1A26003

Dismounting

1) Disconnect negative (–) cable at battery.
2) Remove accessory drive belt. Refer to “Accessory 

Drive Belt and Idler Pulley Removal and Installation: 
For Diesel Engine Model”.

3) Remove Intercooler outlet hose and pipe, if 

necessary.

4) Disconnect generator lead wire (“B” terminal wire) 

(1) and coupler (2) from generator.

5) Remove generator mounting bolts (3).
6) Remove generator (4).

Remounting

1) Mount generator (4) on the generator bracket.
2) Tighten generator mounting bolts (3) to specified 

torque.

Tightening torque
Generator mounting bolt (a):  44 N·m (4.4 kgf-m, 
32.0 lb-ft)

3) Connect “B” terminal wire (1) to generator and then 

tighten “B” terminal nut to specified torque.

Tightening torque
“B” terminal nut (b):  12 N·m (1.2 kgf-m, 9.0 lb-ft)

4) Connect coupler (2) to generator.
5) Install Intercooler outlet hose and pipe, if removed.
6) Install accessory drive belt. Refer to “Accessory 

Drive Belt and Idler Pulley Removal and Installation: 
For Diesel Engine Model”.

7) Connect negative (–) cable at battery.

Generator Disassembly and Assembly

S6JB0A1A26009

Disassembly

NOTE
Before disassembling generator, be sure to 
put match marks at 1 locations (A (drive end 
frame (1) and coil assembly (2)) as shown in 
figure so that any possible mistake can be 
avoided.

 

1) Loosen rear end cover nut (1) and then remove rear 

end cover (2) from coil assembly.

2) Remove insulator (3).

3) Loosen screw (3) and then remove brush holder 

assembly (1) from coil assembly (2).

4) Loosen through bolt (4).

4

3

2

1

I5JB0B1A0008-01

4

3,(a)

2

1

(b)

I5JB0B1A0009-01

2

1

A

I5JB0B1A0010-01

2

1

3

I5JB0B1A0011-01

3

1

2

4

4

I5JB0B1A0012-01

Charging System: For Diesel Engine Model 1J-25

5) Remove coil assembly (1) from rotor (2) and then 

remove wave washer (3).

6) Hold rotor by using vise (2) and loosen pulley nut (6) 

and then remove pulley (1).

CAUTION

!

 

When using vise, put clean cloth (3) and 
aluminium plate (5) between rotor (4) and 
vise (2) so as not to cause damage to rotor.

 

Assembly

1) Insert rotor assembly to drive end frame and then 

install pulley (1).

2) Install pulley nut (6) and then tighten pulley nut.

CAUTION

!

 

When using vise, put clean cloth (3) and 
aluminium plate (5) between rotor (4) and 
vise (2) so as not to cause damage to rotor.

 

3) Install wave washer (3) and coil assembly (2) to rotor 

(1).

NOTE
With marks on drive end frame and coil 
assembly marked before remove aligned to 
each other.

 

4) Install through bolt and then tighten through bolt (1).

5) Install brush holder assembly to coil assembly as 

follows.
a) Depress brush (1) and then while holding it 

depressed, and insert pin (2).

b) Install brush holder assembly (1) to coil 

assembly (2) and then tighten screw (3).

1

2

3

I5JB0B1A0013-01

4

1

5

2

5

3

2

6

I5JB0B1A0014-01

4

1

5

2

5

3

2

6

I5JB0B1A0014-01

1

2

3

I5JB0B1A0013-01

1

1

I5JB0B1A0016-02

2

1

I5JB0B1A0017-01

3

1

2

I5JB0B1A0030-01