Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Alternator

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TESTING



Samurai Models

See Figures 1, 2, 3 and 4

This test procedure should be used if the battery appears undercharged, because of slow cranking or the battery indicator is clear with a red dot.

  1. Ensure that the battery is not discharged because accessories were inadvertently left on.
  2.  
  3. Inspect the alternator drive belt for the proper tension and condition. This is described in detail in General Information & Maintenance of this repair guide.
  4.  
  5. Inspect the system wiring for defects. Check all connections for tightness and cleanliness, including the slip connectors at the alternator and firewall, the cable connections at the battery, and the starter and ignition ground cable.
  6.  



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Fig. Fig. 1: To test the alternator, connect an ammeter and a voltmeter in the charging circuit, as indicated



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Fig. Fig. 2: The voltage exhibited by the voltmeter depends upon the temperature of the regulator case. The voltage should fall within the shaded area of the chart-1986-89 Samurai models



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Fig. Fig. 3: For 1990-95 Samurai models, the output voltage should fall within the shaded area of the chart

  1. Install a voltmeter and an ammeter in the charging system wiring circuit as shown in the accompanying illustration.
    1. The voltmeter should be installed between alternator terminal B and ground.
    2.  
    3. The ammeter should be attached between alternator terminal B and the battery positive (+) terminal.
    4.  

  2.  

The test specifications are given for components at 77°F (25°C). It should be taken into consideration that the voltage will vary somewhat with regulator case temperature. Refer to the accompanying charts for approximate temperature-to-voltage changes.

  1. While observing the voltmeter and ammeter, have an assistant start the engine and run it from idle up to 2,000 rpm. Turn the engine OFF . The amperage should reach a maximum of 10 amps, and the voltage should stay between 14.2-14.8 volts
    1. If the voltage was higher than specified, either replace the alternator with a new one or have it rebuilt with a new regulator.
    2.  
    3. If the voltage was within the specified range skip to Step 7.
    4.  
    5. If the voltage was lower than the specified minimum, perform the next step.
    6.  



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    Fig. Fig. 4: Use a jumper wire to ground alternator terminal F during the testing procedure

  2.  
  3. Using a jumper wire, ground alternator terminal F and start the engine again. Observe the voltage at terminal B again. Shut the engine OFF .
    1. If the voltage was above the specified range in Step 5, either replace the alternator with a new one or have it rebuilt with a new regulator.
    2.  
    3. If the voltage was within or below the specified range, proceed to the next step.
    4.  
    5. If the voltage was below the specified range, repair or replace the alternator.
    6.  

  4.  
  5. Have your assistant, start the engine, run it at 2,000 rpm and turn the headlamps and heater blower motor on, while you observe the ammeter. The alternator should produce at least 20 amps.
    1. If the alternator does not produce at least 20 amps, repair or replace the alternator.
    2.  
    3. If the alternator does produce 20 amps or more, it is working properly.
    4.  

  6.  

Sidekick, Tracker, X-90 and Sidekick Sport Models

See Figures 1, 5 and 6

This test procedure should be used if the battery appears undercharged, because of slow cranking or the battery indicator is clear with a red dot.

  1. Ensure that the battery is not discharged because accessories were inadvertently left on.
  2.  
  3. Inspect the alternator drive belt for the proper tension and condition. This is described in detail in General Information & Maintenance of this repair guide.
  4.  
  5. Inspect the system wiring for defects. Check all connections for tightness and cleanliness, including the slip connectors at the alternator and firewall, the cable connections at the battery, and the starter and ignition ground cable.
  6.  
  7. Install a voltmeter and an ammeter in the charging system wiring circuit as shown in the accompanying illustration.
    1. The voltmeter should be installed between alternator terminal B and ground.
    2.  
    3. The ammeter should be attached between alternator terminal B and the battery positive (+) terminal.

      Click image to see an enlarged view

      Fig. Fig. 5: Depending upon the temperature of the regulator case, the voltage should fall somewhere within the shaded area of the chart-Sidekick, Tracker and X-90 models



      Click image to see an enlarged view

      Fig. Fig. 6: For Sidekick Sport models, the output voltage should fall within the shaded area of this chart

    4.  

  8.  
  9. Turn off all accessories, such as the wipers, the heater blower motor, etc.
  10.  

The test specifications are given for components at 68°F (20°C). It should be taken into consideration that the voltage will vary somewhat with regulator case temperature. Refer to the accompanying charts for approximate temperature-to-voltage changes.

  1. While observing the voltmeter and ammeter, have an assistant start the engine and run it from idle up to 2,000 rpm. Turn the engine OFF . The amperage should reach a maximum of 10 amps, and the voltage should stay between 14.4-15.0 volts
    1. If the voltage was higher than specified, either repair or replace the alternator.
    2.  
    3. If the voltage was within the specified range, perform the next step.
    4.  
    5. If the voltage was lower than the specified minimum, perform the next step.
    6.  

  2.  
  3. Have your assistant, start the engine, run it at 2,000 rpm and turn the headlamps and heater blower motor on, while you observe the ammeter. The alternator should produce at least 20 amps.
    1. If the alternator does not produce at least 20 amps, repair or replace the alternator.
    2.  
    3. If the alternator does produce 20 amps or more, it is working properly.
    4.  

  4.  

REMOVAL & INSTALLATION



Disconnecting the battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is resconnected.

Samurai Models
  1. Disconnect the negative battery cable.
  2.  
  3. From under the vehicle, label and detach all wiring from the alternator.
  4.  
  5. Disengage the brake pipe from the clamp on the radiator shield, then remove the shield.
  6.  
  7. Loosen the mounting bolts, then remove the alternator drive belt from the pulley.
  8.  
  9. While supporting the alternator, remove the mounting bolts and lower the alternator down and out of the engine compartment.
  10.  

To install:
  1. Hold the alternator in position, then install the mounting bolts finger-tight.
  2.  
  3. Position the alternator drive belt around the pulley, then adjust the drive belt tension as described in General Information & Maintenance .
  4.  
  5. Tighten the mounting bolts securely.
  6.  
  7. Reattach all wiring to the alternator.
  8.  
  9. Install the lower radiator shield and connect the brake pipe to the mounting clamp.
  10.  
  11. Connect the negative battery cable.
  12.  

Sidekick, Tracker, X-90 and Sidekick Sport Models

See Figures 7, 8, 9 and 10

  1. Disconnect the negative battery cable.
  2.  
  3. On Sidekick Sport models, remove the air inlet hose.
  4.  
  5. Label and detach all wiring from the alternator.
  6.  
  7. Remove the evaporative charcoal canister and mounting bracket from the engine compartment.
  8.  
  9. On Sidekick Sport models, remove the clamps from the alternator mounting bracket and engine mounting bracket.
  10.  



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Fig. Fig. 7: To remove the alternator on Sidekick Sport models, disconnect the negative battery cable ...



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Fig. Fig. 8: ... then remove the air inlet hose from the throttle body and air cleaner housing



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Fig. Fig. 9: Detach all wiring and any wiring clamps from the alternator



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Fig. Fig. 10: Remove the alternator mounting bolts and lift the alternator up and out of the engine compartment

  1. Loosen the mounting bolts, then remove the alternator drive belt from the pulley.
  2.  
  3. While supporting the alternator, remove the mounting bolts and lift the alternator up and out of the engine compartment.
  4.  

To install:
  1. Hold the alternator in position, then install the mounting bolts finger-tight.
  2.  
  3. Position the alternator drive belt around the pulley, then adjust the drive belt tension as described in General Information & Maintenance .
  4.  
  5. Tighten the alternator mounting bolts to 17 ft. lbs. (23 Nm).
  6.  
  7. On Sidekick Sport models, install the clamps onto the alternator and engine mounting brackets.
  8.  
  9. Reattach all wiring to the alternator.
  10.  
  11. Install the evaporative charcoal canister and mounting bracket.
  12.  
  13. On Sidekick Sport models, install the air inlet hose.
  14.  
  15. Connect the negative battery cable.
  16.  

 
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