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Generators & Regulators BMW M3 E46

Charging System 35 illustrations ~1088 words

DESCRIPTION

There are 2 generators available for these vehicles; Valeo or Bosch. Some procedures are specific to each type.

GENERATOR & REGULATOR SWITCH (SINGLE FUNCTION REGULATOR)

  1. Check for correct connections on fully charged battery, generator and starter motor. Check for good ground connection between engine and body. Check for properly tightened drive belt.
  2. Connect DIS tester. Go to Measurement, Checking Alternator.
  3. If charge indicator lamp is permanently lit, remove voltage regulator and check carbon brushes. If Bosch voltage regulator, see «VOLTAGE REGULATOR (BOSCH)»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators__voltage-regulator-bosch) under REMOVAL & INSTALLATION. If Valeo voltage regulator, see «VOLTAGE REGULATOR (VALEO)»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators__voltage-regulator-valeo) under REMOVAL & INSTALLATION. Minimum length of carbon brushes "A" is 5 mm. (Scheme 1) Replace, if necessary.
  4. If charge indicator lamp goes out while engine is running, check control voltage. Constant voltage regulation should be 14.3 volts. Regulator switch must be replaced if control voltage is not achieved. If Bosch voltage regulator, see «VOLTAGE REGULATOR (BOSCH)»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators__voltage-regulator-bosch) under REMOVAL & INSTALLATION. If Valeo voltage regulator, see «VOLTAGE REGULATOR (VALEO)»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators__voltage-regulator-valeo) under REMOVAL & INSTALLATION.

Scheme 1

Scheme 1
Scheme 1

GENERATOR & REGULATOR SWITCH (MULTIFUNCTION REGULATOR)

Note. Multifunction regulator is recognizable by plug connection on regulator.

Check for correct connections on fully charged battery, generator and starter motor. Check for good ground connection between engine and body. Check for properly tightened drive belt. Connect DIS tester. Go to Function Selection, Complete Vehicle, Drive, Voltage And Current Regulation, Voltage And Current Generation. Work through test modules. To diagnose oscillograms for each fault, see GENERATOR OSCILLOGRAMS . If generator is faulty, repair or replace it. To replace, see GENERATOR under REMOVAL & INSTALLATION.

FaultOscillogram
Fault-Free(Scheme 2)
One Phase Interrupted(Scheme 3)
Internal Fault(Scheme 4)
Open Circuit In Negative Diode(Scheme 5)
Short Circuit In Positive Diode(Scheme 6)
Open Circuit In Positive Diode(Scheme 7)
Open Circuit In Exciter Diode(Scheme 8)

GENERATOR OSCILLOGRAMS

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

REMOVAL & INSTALLATION

CAUTIONDisconnecting vehicle battery will cancel fault codes of control units. On vehicles with radio codes, after disconnecting battery, radio codes must be re-entered. Obtain radio code card from customer. Note stored stations and restore then after connecting battery. Also, where applicable, initialize sunroof and set steering angle.

A/C COMPRESSOR DRIVE BELT

Note. If drive belt is to be reused, mark direction of travel and reinstall drive belt in same direction.

  1. If necessary, remove splash guard. On models with hydraulic drive belt and tension jack, remove dust cab, push back belt tensioner at bolt connection of guide pulley and remove drive belt. (Scheme 9) On models with mechanical drive belt and tension jack, press back drive belt tensioner at hexagon head or Torx socket and remove drive belt. (Scheme 10)
  2. Check drive belt for coolant and oil residues. To install, reverse removal procedure. Replace if necessary. Make sure belt is correctly positioned on belt pulleys.

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

FAN CLUTCH

Note. Left-hand threads.

  1. If necessary, remove air duct. On M3, remove engine underguard and release fan cowl.
  2. Using Special Tool (11 5 030), grip pulley and unfasten cap nut from water pump using Special Tool (11 5 040). (Scheme 11) If necessary, unfasten fan cowl. Take fan wheel with fan coupling off water pump and remove. Unfasten screws and remove fan from fan coupling. (Scheme 12)
  3. To install, reverse removal procedure. Tighten fan impeller using Special Tool (11 5 040). When using special tool, 22 Ft. Lbs. (30 Nm) on torque wrench scale is equal to a tightening torque of 30 Ft. Lbs. (40 N.m). Tighten to specification. See «TORQUE SPECIFICATIONS»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators__torque-specifications).

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12
CAUTIONDisconnecting vehicle battery will cancel fault codes of control units. On vehicles with radio codes, after disconnecting battery, radio codes must be re-entered. Obtain radio code card from customer. Note stored stations and restore then after connecting battery. Also, where applicable, initialize sunroof and set steering angle.

Removal

  1. Retrieve fault codes. Turn off ignition. Disconnect and cover battery negative terminal.
  2. Remove intake filter housing. See «INTAKE FILTER HOUSING»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators). Remove fan clutch. See «FAN CLUTCH»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators__fan-clutch). Remove generator drive belt. See «GENERATOR DRIVE BELT»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators__generator-drive-belt).
  3. If necessary, drain supply tank for power steering pump, remove with holder and place to one side. Lines on supply tank remain connected.
  4. If fitted, remove air hose. (Scheme 13)
  5. On version 1, take off cap on connections. (Scheme 14) Disconnect plug connection (1). Remove nut (2) and disconnect wire from battery positive lead. On version 2, unlock and detach plug connection (1). (Scheme 15) Remove nut (2) and disconnect wire from battery positive lead.
  6. On version without idler pulley, remove generator screws in succession while gripping generator firmly. (Scheme 16) Remove generator. On version with idler pulley, remove cover from idler pulley (1). (Scheme 17) Remove screw and remove idler pulley (1). Remove screw and remove generator (2).

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Installation

  1. To install, reverse removal procedure. On version with idler pulley, turning lock of tensioning roller must engage in generator groove. (Scheme 18)
  2. Tighten wire from battery positive lead to specification. See «TORQUE SPECIFICATIONS»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators__torque-specifications).
  3. Interrogate fault memory of DME control unit. Clear fault memory.

Scheme 18

Scheme 18
Scheme 18

GENERATOR DRIVE BELT

Note. If drive belt is to be reused, mark direction of travel and reinstall drive belt in same direction.

  1. Remove fan clutch with fan impeller. See «FAN CLUTCH»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators__fan-clutch).
  2. Remove A/C compressor drive belt. See «A/C COMPRESSOR DRIVE BELT»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators__ac-compressor-drive-belt).
  3. Remove cap from tensioning roller. (Scheme 19)
  4. Relieve tension on belt drive. (Scheme 20) Remove drive belt.
  5. Check drive belt for coolant and oil residues. Replace if necessary.
  6. To install, reverse removal procedure. Check that belt is correctly positioned on belt pulleys. For version without auxiliary tensioning roller (Scheme 21) For version with auxiliary tensioning roller (Scheme 22) Locking device of auxiliary tensioning roller must snap into groove on generator. (Scheme 23)

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23
  1. Turn off ignition. Detach holder (1) for engine wiring harness. (Scheme 24) Unlock retainers (2) and release screws (3). Remove intake filter housing.
  2. To install, check seal (1) between air-mass flow sensor and air cleaner upper section for damage. (Scheme 25) Replace if damaged. Coat gasket with acid-free grease.
  3. On M54, install guide rail (1) on intake filter housing on rubber mount (2). (Scheme 26)

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

VOLTAGE REGULATOR (BOSCH)

CAUTIONDisconnecting vehicle battery will cancel fault codes of control units. On vehicles with radio codes, after disconnecting battery, radio codes must be re-entered. Obtain radio code card from customer. Note stored stations and restore then after connecting battery. Also, where applicable, initialize sunroof and set steering angle.
  1. Turn off ignition. Retrieve fault codes. Disconnect battery ground wire from generator. Remove generator. See «GENERATOR»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators).
  2. Release bolts on cover. (Scheme 27)
  3. Remove regulator switch. Check contact surfaces of collector rings for wear and recondition if necessary.

Scheme 27

Scheme 27
Scheme 27

VOLTAGE REGULATOR (VALEO)

CAUTIONDisconnecting vehicle battery will cancel fault codes of control units. On vehicles with radio codes, after disconnecting battery, radio codes must be re-entered. Obtain radio code card from customer. Note stored stations and restore then after connecting battery. Also, where applicable, initialize sunroof and set steering angle.
  1. Turn off ignition. Retrieve fault codes. Disconnect battery ground wire. Remove generator. See «GENERATOR»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators).
  2. Remove nuts on cover. (Scheme 28)
  3. Remove screws. Remove regulator switch. (Scheme 29)
  4. Check contact surfaces (1) of collector rings for wear and recondition if necessary. (Scheme 30)

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30
  1. Install regulator switch with assembly cap. Hand tighten nuts of regulator switch. Remove assembly cap (1). (Scheme 31)
  2. Fit supplied cover cap (2). (Scheme 32) Tighten nuts and ground screw of regulator switch to specification. See «TORQUE SPECIFICATIONS»(/bmw/m3/e46-1999-2006/remont/charging-system/#generators-regulators__torque-specifications).

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m.)
Fan Clutch On Water Pump30 (40)
INCH Lbs. (N.m)
Regulator Switch
4 mm18 (2)
5 mm35 (4)
Battery Leads35-53 (4-6)
Wires-To-Generator115 (13)

TORQUE SPECIFICATIONS

Scheme 33

Scheme 33: WIRING DIAGRAMS
Scheme 33: WIRING DIAGRAMS

Scheme 34

Scheme 34
Scheme 34

Scheme 35

Scheme 35
Scheme 35

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