Suzuki Grand Vitara JB419. Manual - part 72

Charging System:  1J-9

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

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4

1

5

2

5

3

2

6

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4

1

5

2

5

3

2

6

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1

2

3

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1

1

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2

1

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3

1

2

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1J-10 Charging System: 

c) Remove pin from brush holder.

6) Install insulator (3).
7) Install rear end cover (2) to coil assembly and tighten 

rear end cover nut (1) to specified torque.

8) Make sure that rotor turns smoothly.

Drive End Frame / Bearing Disassembly and 
Assembly

S5JB0B1A06010

Disassembly

1) Loosen screw (3) and then remove bearing retainer 

(1) from drive end frame (2).

2) Push out drive end bearing by using hydraulic press 

(1) and special tools.

Special tool
(A):  09913–75821 

Assembly

1) Press-fit drive end bearing by using special tools and 

press (1).

Special tool
(A):  09913–76010 

CAUTION

!

 

Be sure to use new bearing.

 

2) Install bearing retainer to drive end frame and tighten 

screw.

Generator Inspection

S5JB0B1A06005

Rotor

1) Using an ohmmeter, check for continuity between 

slip rings of rotor. If there is no continuity, replace the 
rotor assembly.

2) Using an ohmmeter, check that there is no continuity 

between slip ring and rotor. If there is continuity, 
replace the rotor assembly.

3) Check slip rings for roughness or scoring. If rough or 

scored, replace the rotor assembly.

2

1

3

I5JB0B1A0011-01

3

1

3

2

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1

A

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1

A

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IYSQ011A0042-01

IYSQ011A0043-01

Charging System:  1J-11

Stator

1) Check resistance between the following leads of 

stator. If there is no continuity, replace coil assembly.

Stator lead resistance

2) Using an ohmmeter, check that there is no continuity 

between coil leads and stator core. If there is 
continuity, replace coil assembly.

Brush and Brush Holder
Check each brush for wear by measuring its length (a) 
as shown. If the brush is found worn down, replace the 
brush. 

Rectifier

1) Check continuity of rectifier by using an ohm meter.
2) Reverse the polarity of the tester probes and repeat 

Step 1).

3) Check that one shows continuity and the other 

shows no continuity.
If there is continuity, replace coil assembly.

Bearing
• Check that drive and bearing is not rough or worn.

• Check that end housing bearing is not rough or worn.

Stator lead 

Resistance

1 - 2

continuity

1 - 3
4 - 5
4 - 6

1

2

3

4

5

6

I5JB0B1A0022-01

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a

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IYSQ011A0051-01

1J-12 Charging System: 

Accessory Drive Belt and Idler Pulley Removal 
and Installation

S5JB0B1A06006

Removal

WARNING

!

 

Disconnect negative (–) cable at battery 
before removing and installing generator 
belt.

 

1) Remove engine under cover.
2) Loosen tensioner by turning the tensioner (1) 

clockwise.

3) While holding the tensioner and belt loose.
4) Loosen tensioner bolt No.1 (2) and remove breather 

front No.1 hose clip (3).

5) Remove accessory drive belt (4).

CAUTION

!

 

Do not apply any oil or grease to the 
accessory drive belt.

 

6) Loosen idler pulley bolt (7) and then remove idler 

pulley (5) and adapter (6).

Installation

1) Install adapter (6) and then tighten adapter.
2) Install idler pulley (5) and then tighten idler pulley 

bolt (7) to specified torque.

Tightening torque
Idler pulley bolt (b):  50 N·m (5.0 kgf-m, 36.5 lb-ft)

3) Install accessory drive belt (4).
4) Tighten tensioner bolt No.1 (2) and install breather 

front No.1 hose clip (3).

Tightening torque
Accessory drive belt and belt tensioner bolt 
No.1 (a):  50 N·m (5.0 kgf-m, 36.5 lb-ft)

5) Loosen tensioner by turning the tensioner (1) 

clockwise.

6) While holding the tensioner, install accessory drive 

belt (4).

NOTE
Make sure that the belt fits each pulley’s 
groove properly.

 

7) Install engine under cover.

1

2

3

4

5

6

5

7

I5JB0B1A0027-01

1

2,(a)

3

4

5

6

5

7,(b)

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