Suzuki Vitara, Grand Vitara, XL7 2000-06

Alternator

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Diagnosis & Testing



Ensure the battery is fully charged. Check battery terminals making sure they are clean and tight. Listen for any abnormal noises coming from alternator. Inspect drive belt for proper tension. Check charging system for proper voltage output. Ensure fuses and fusible links are not blown. Install scan tool for additional testing.

Installation



Install or connect the following:



Alternator
 
Alternator mounting bracket. Tighten the bolts to 20 ft. lbs. (27 Nm).
 
Alternator harness connectors
 
Accessory drive belt. Tighten the alternator bolts to 24 ft. lbs. (33 Nm).
 
EVAP canister
 
Negative battery cable
 

Removal



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Evaporative Emission (EVAP) canister
     
    Accessory drive belt
     
    Alternator harness connectors
     
    Alternator mounting bracket
     
    Alternator
     

  4.  

Removal & Installation



1.6L & 2.5L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect alternator lead wire and coupler from alternator.
  4.  
  5. Remove alternator belt.
  6.  
  7. Remove alternator drive belt adjusting bolt and alternator mounting bolt.
  8.  
  9. Remove alternator.
  10.  

To install:

  1. Mount alternator on the alternator bracket.
  2.  
  3. Install alternator adjusting and mounting bolts.
  4.  
  5. Install alternator belt.
  6.  
  7. Tighten alternator belt.
  8.  
  9. Retighten mounting bolt to 17 ft. lbs. (23 Nm).
  10.  
  11. Connect terminal lead wire and coupler to alternator.
  12.  
  13. Connect the negative battery cable.
  14.  

2.0L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Loosen belt tensioner by turning the tensioner pulley clockwise.
  4.  
  5. While holding the tensioner and belt loose, remove alternator belt.
  6.  
  7. Disconnect alternator lead wire and coupler from alternator.
  8.  
  9. Remove alternator mounting bolts.
  10.  
  11. Remove alternator.
  12.  

To install:

  1. Install alternator and mounting bolts.
  2.  
  3. Tighten mounting bolts to 17 ft. lbs. (23 Nm).
  4.  
  5. Connect terminal lead wire and coupler to alternator.
  6.  
  7. Loosen belt tensioner by turning the tensioner pulley clockwise.
  8.  
  9. While holding the tensioner, install alternator belt.
  10.  

2.7L Engine
  1. Disconnect negative cable at battery.
  2.  
  3. Remove air cleaner case and hose.
  4.  
  5. Disconnect alternator lead wire and coupler from alternator.
  6.  
  7. Remove water pump and alternator drive belt.
  8.  
  9. Remove alternator bracket bolt and then remove bracket.
  10.  
  11. Remove alternator mounting bolts.
  12.  
  13. Remove alternator.
  14.  

To install:

  1. Install bracket and then tighten alternator bracket bolt to 32 ft. lbs. (45 Nm).
  2.  
  3. Mount alternator on the alternator bracket.
  4.  
  5. Tighten alternator mounting bolts, upper to 18 ft. lbs. (25 Nm), lower to 32 ft. lbs. (45 Nm).
  6.  
  7. Install water pump and alternator drive belt.
  8.  
  9. Connect terminal lead wire and coupler to alternator.
  10.  
  11. Install air cleaner case and hose.
  12.  
  13. Connect negative cable at battery.
  14.  

 
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