Suzuki Aerio, Verona 2002-06

Alternator

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Diagnosis & Testing



The alternator provides power consuming components with current while the engine is running and maintains battery charge. The alternator is mounted on the front edge of the engine. The output of the alternator depends on engine speed. When the engine is idling, the alternator operates at approximately half of maximum output. When the engine is idling with many power consuming components engaged, the alternator may be unable to maintain full battery charge.

The alternator creates an alternating current which is converted to a direct current in the rectifier bridge. The alternator also utilizes a built-in voltage regulator.

  1. Check that the wiring is in good condition.
  2.  
  3. Check for any abnormal noise from the alternator while the engine is running.
  4.  
  5. Check the accessory drive belt for wear or slipping.
    NOTE
    With the engine running at 2500 RPM, headlights on and fan blower on high, the alternator output voltage should be 13.9-14.6 volts at 68°F.

  6.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner outlet hose and air cleaner assembly
     
    Power steering return pipe clamp bolt
     
    Right side drive shaft
     
    Right engine under cover
     
    Serpentine drive belt
     
    Power steering suction hose
     
    Union bolt
     
    Power steering high pressure pipe and gasket
     
    Power steering pressure switch connector
     
    Power steering pump bolts
     
    Power steering pump
     
    B terminal wire and connector from the alternator
     
    Alternator cover
     
    Alternator mounting bolts
     
    Alternator
     

  4.  

To install:

  1. Install or connect the following:

    Alternator
     
    Alternator mounting bolts. Tighten to upper bolt to 16 ft. lbs. (23 Nm); and lower bolt to 37 ft. lbs. (50 Nm).
     
    Alternator cover
     
    B terminal wire and connector to the alternator
     
    Power steering pump and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Power steering pressure switch connector
     
    Power steering high pressure pipe and gasket
     
    Union bolt and tighten to 26 ft. lbs. (55 Nm)
     
    Power steering suction hose
     
    Serpentine drive belt
     
    Right engine under cover
     
    Right side drive shaft
     
    Power steering return pipe clamp bolt
     
    Air cleaner outlet hose and air cleaner assembly
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Serpentine accessory drive belt by turning the automatic tensioner roller bolt clockwise to relieve tension on the belt
     
    Harness connector from the back of the alternator
     
    Alternator lead to the battery
     
    Alternator bolts and alternator
     

  4.  

To install:

  1. Install or connect the following:

    Alternator
     
    Alternator mounting bolts. Tighten to upper bolt to 26 ft. lbs. (35 Nm); and lower bolt to 30 ft. lbs. (40 Nm).
     
    Alternator lead to the battery
     
    Harness connector to the back of the alternator
     
    Serpentine accessory drive belt. Relieve tension on the belt by first applying downward pressure on the automatic tension roller bolt and releasing pressure once the belt is in place.
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Alternator mounting-Verona

     

  2.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Power steering pump
     
    Turbocharger hose
     
    Alternator harness connectors
     
    Alternator

    Click image to see an enlarged view

    Fig. Alternator mounting

     

  4.  

To install:

Install or connect the following:



Alternator
 
Alternator harness connectors
 
Turbocharger hose
 
Power steering pump
 
Accessory drive belt
 
Negative battery cable
 

6-Cylinder Engines
  1. Disconnect the battery negative lead.
  2.  
  3. Raise the car.
  4.  
  5. Remove the lower cover plate.
  6.  
  7. Drain the coolant.
  8.  
  9. Install the lower splash guard.
  10.  
  11. Lower the car.
  12.  
  13. Remove the upper engine coolant hose.
  14.  
  15. Remove the auxiliary belt.
  16.  
  17. Remove the power steering pump.
  18.  
  19. Disconnect the turbocharger hose from the cooling system. Push the hose to one side.
  20.  
  21. Remove the right-hand headlamp.
  22.  
  23. Detach the bumper cover on the right-hand side.
  24.  
  25. Remove the bolts from the front panel on the right-hand side as illustrated.
  26.  
  27. Remove the bolt that runs through the upper mounting and the lower bolts.
  28.  
  29. With AC, slacken off the lower bolts for the compressor, to provide clearance.
  30.  
  31. Disconnect the battery positive lead.
  32.  
  33. Disconnect the connector.
  34.  
  35. Remove the alternator .
  36.  
  37. Turn the alternator into position.
  38.  
  39. Carefully pry the front panel forwards.
  40.  
  41. Pull the alternator upwards and out.
  42.  

To install:

  1. Position the alternator. Install the bolt through the upper mounting. Do not tighten.
  2.  
  3. Connect the cable and the connector.
  4.  
  5. Install the lower bolts for the alternator (upper bolts for the compressor).
  6.  
  7. With AC, tighten the 2 lower bolts for the compressor.
  8.  
  9. Tighten the 3 bolts for the alternator.
  10.  
  11. Install:

    The front panel
     
    The bumper cover
     
    The right-hand headlamp
     
    The turbocharger hose
     
    The power steering pump
     
    The accessory drive belt
     
    The engine coolant hose. Top up the coolant
     
    The battery negative lead
     

  12.  

8-Cylinder Engines
  1. Disconnect the battery negative cable.
  2.  
  3. Remove the auxiliary drive belt.
  4.  
  5. Detach the rear ignition coil cover on the right-hand side. Pull straight up and fold it aside.
  6.  
  7. Remove the right-hand halfshaft.
  8.  
  9. Remove the cover to the wheel arch
  10.  
  11. Remove the plastic nuts.
  12.  
  13. Removing the fuel line brackets
  14.  
  15. Remove the bolts and nuts.
  16.  
  17. Move the fuel lines to the side.
  18.  
  19. Lift the alternator out through the wheel arch.

    Click image to see an enlarged view

    Fig. Alternator mounting-8-cylinder engines

  20.  

To install:

  1. Lift the alternator into position.
  2.  
  3. Install the bolts and connect the battery cable.
  4.  
  5. Install the fuel lines
  6.  
  7. Install the cover to the wheel arch
  8.  
  9. Install the right-hand halfshaft
  10.  
  11. Install the fuel pipe
  12.  
  13. Press in the ignition coil cover.
  14.  
  15. Install the auxiliary belt.
  16.  
  17. Connect the battery negative cable.
  18.  

 
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