Forenza 2007

Voltage Regulator

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Adjustments



Specific to:

Suzuki Forenza 2007-2008

Suzuki Reno 2007-2008


NOTE
CS generators use a new type of regulator that incorporates a diode trio. A Delta stator, a rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier generators. A conventional pulley and fan are used. There is no test hole.

No adjustments can be made to the alternator, if under or over charging follow the system diagnostic checks.

Removal & Installation



Specific to:

Suzuki Forenza 2007-2008

Suzuki Reno 2007-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Mark a match line that cannot easily be removed on the end frame to make assembly easier.
  6.  
  7. Pry off the plastic cover to expose the stator connections.
  8.  
  9. Remove the stator connections from the rectifier bridge terminals by cutting the wires.
  10.  
  11. Pry off the baffle.
  12.  
  13. Remove the rectifier/regulator/brush holder assembly screws.
  14.  
  15. Remove the brush holder assembly and the regulator.

    Click image to see an enlarged view

    Fig. View of the alternator



    Click image to see an enlarged view

    Fig. Alternator voltage regulator

  16.  
  17. Test the rectifier bridge by connecting the ohmmeter terminals to the bridge and the heat sink.

    Click image to see an enlarged view

    Fig. Alternator rectifier bridge test

  18.  
  19. Retest by connecting the ohmmeter terminals in reverse.

    Click image to see an enlarged view

    Fig. Alternator diode test

  20.  
  21. Replace the rectifier bridge, if each reading is the same.
  22.  
  23. Test the remaining two diodes after the above procedure.
  24.  
  25. Test the diodes by connecting the ohmmeter terminals to the bridge terminal and the base plate.
    NOTE
    If the reading is the same, replace the rectifier bridge.

  26.  
  27. Remove the generator through -bolts.
  28.  
  29. Move to the drive end of the generator and remove the drive end bearing nut.
  30.  
  31. Remove the pulley and the collars.

    Click image to see an enlarged view

    Fig. Alternator disassembly

  32.  
  33. Test the rotor for an open circuit using the ohmmeter with the drive end frame assembled.
    NOTE
    The reading should be sufficiently high, or the rotor must be replaced.



    Click image to see an enlarged view

    Fig. Alternator rotor test drive end assembled

  34.  
  35. Test the rotor for open and short circuits. The reading should be 1.7 -2.3 ohms, or the rotor should be replaced.

    Click image to see an enlarged view

    Fig. Alternator rotor test

  36.  
  37. Remove the drive end frame from the shaft.
  38.  
  39. For vehicles with an internal generator fan, remove the drive end frame and the fan.

    Click image to see an enlarged view

    Fig. Alternator fan (internal)

  40.  
  41. Remove the stator.
  42.  
  43. Test the stator for an open circuit using the ohmmeter.

    Click image to see an enlarged view

    Fig. Alternator fan (internal)

  44.  
  45. Remove the ring in the slip ring end frame.

    Click image to see an enlarged view

    Fig. Alternator fan (internal)

  46.  

To install:

  1. Install the new ring in the slip ring end frame.
  2.  
  3. Install the stator.
  4.  
  5. Position the rotor assembly shaft with the drive end frame in the slip ring end assembly until the gap between the outer lace and the end frame casting is 0.075 in (1.9 mm.).
  6.  
  7. Install the generator through-bolts.
  8.  
  9. Tighten the generator through-bolts to 89 inch lbs. (10 Nm).
  10.  
  11. Position the fan, the collars, and the pulley on the rotor shaft and secure with the nut.
  12.  
  13. Tighten the generator drive end bearing nut to 60ft. lbs. (81 Nm).
  14.  
  15. Install the generator.
  16.  
  17. Weld the brush holder terminal to the regulator terminal, if removed.
  18.  
  19. Fix the brush holder with the retainer pin, and weld the regulator/brush holder assembled terminal to the rectifier terminal.
  20.  
  21. Apply silicone grease between the bridge and the end frame for radiation purposes.
  22.  
  23. Fasten the screws holding the rectifier regulator/brush holder assembly to the end frame.
  24.  
  25. Punch the new baffle with the pin into the brush.
  26.  
  27. Weld the connectors of the rectifier bridge.
  28.  
  29. Connect the negative battery cable.
  30.  

 
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