Generators & Regulators BMW X5 E53

IDENTIFICATION

CHASSIS & ENGINE IDENTIFICATION

DESCRIPTION

Bosch or Valeo generators are installed in X5 vehicles. They are fitted depending on type of engine and equipment configuration. They differ with regard to their rating of 140 A and 170 A and are air cooled. X5 vehicles with 4.4L and 4.6L engines have generators which are cooled by coolant jackets.

GENERATOR & REGULATOR SWITCH

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. Search down through the following

1. FUNCTION SELECTION
2. COMPLETE VEHICLE
3. DRIVE
4. VOLTAGE AND CURRENT REGULATION
5. 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 generator on 3.0L (M54), see

GENERATOR 3.0L (M54)

under REMOVAL & INSTALLATION. To replace generator on 4.4L & 4.6L (M62), see

GENERATOR 4.4L & 4.6L (M62)

under REMOVAL & INSTALLATION. To replace generator on 4.4L (N62), see

GENERATOR 4.4L (N62)

under REMOVAL & INSTALLATION.

If regulator is faulty, replace it. To replace Bosch regulator, see VOLTAGE REGULATOR (BOSCH) . To replace Valeo regulator, see VOLTAGE REGULATOR (VALEO) . To replace regulator on 4.4L (N62) see VOLTAGE REGULATOR 4.4L (N62) .

GENERATOR OSCILLOGRAMS

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

REMOVAL & INSTALLATION

A/C COMPRESSOR DRIVE BELT 3.0L (M54)

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 cap, push back belt tensioner at bolt connection of guide pulley and remove drive belt. (Scheme 8) 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 9)
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 8

Scheme 9

A/C COMPRESSOR DRIVE BELT 4.4L (N62)

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

Note. If drive belt is contaminated with hydraulic fluid, replace it.

1. Remove generator drive belt. See «GENERATOR DRIVE BELT 4.4L (N62)»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__generator-drive-belt-44l-48l).
2. Remove engine splash guard.
3. Pretension belt tensioner slowly and carefully with a Torx socket as far as it will go and secure with Special Tool (11 3 340). (Scheme 10) Remove drive belt.
4. To install, reverse removal procedure. Check that drive belt is correctly positioned on pulleys. (Scheme 11)

Scheme 10

Scheme 11

1. Retrieve fault codes of DME control unit. Switch off ignition.
2. Unlock plug (1) and detach. (Scheme 12) Open retainers (2). Release hose clamp (3) and detach intake hose (5) from air-mass flow sensor (4). Pull air-mass flow sensor out of intake filter housing.
3. To install, reverse removal procedure. Check sealing ring (1) between air-mass flow sensor and intake hose for damage. (Scheme 13) Replace, if necessary. Coat sealing ring (1) with acid-free grease.
4. Check sealing ring (1) between air-mass flow sensor and intake filter housing for damage. (Scheme 14) Replace, if necessary. Coat sealing ring (1) with acid-free grease.
5. Install air-mass flow sensor between intake filter housing and intake hose so that arrow points in direction of intake hose. (Scheme 15)
6. Retrieve and correct fault codes of DME control module. Clear fault memory.

Scheme 12

Scheme 13

Scheme 14

Scheme 15

FAN CLUTCH

Note. Fan clutch bolts have left-hand threads.

1. If necessary, remove air duct.
2. On 3.0L (M54), use Special Tool (11 5 030). Grip pulley and unfasten cap nut from water pump using Special Tool (11 5 040). (Scheme 16) On 4.4L and 4.6L (M62), use Special Tool (11 5 050). 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 17)
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/x5/e53-1999-2003/remont/charging-system/#generators-regulators__torque-specifications).

Scheme 16

Scheme 17

1. Lever out fan cowl cover expansion rivets. (1). (Scheme 18) Remove screws (2).
2. Intake pipe is secured in intake hood by 2 retaining lugs (1). (Scheme 19) Retaining lugs are located under intake hood. Press in retaining lugs (1) and remove intake hood.
3. Unclip water hose (1) from holder on fan cowl. For purposes of clarity, figure is shown from below. Underbody paneling does not have to be removed. Water hose (1) can be pulled out of holder from above. (Scheme 20)
4. Remove fan impeller with fan clutch. See «FAN CLUTCH»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__fan-clutch).
5. Detach plug (1) from Automatic Recirculated Air Control (AUC) sensor. (Scheme 21) Unlock plug connection (2) and unclip cable.
6. Lever out expansion rivets (1). (Scheme 22) Remove fan cowl towards top.
7. To install, reverse removal procedure. Attach lugs (1) to holders on radiator. (Scheme 23) Tighten intake hood screws (2) to specification. See «TORQUE SPECIFICATIONS»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__torque-specifications).

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

GENERATOR 3.0L (M54)

Removal

1. Retrieve fault codes. Turn off ignition. Disconnect and cover battery negative terminal.
2. Remove intake filter housing. See «INTAKE FILTER HOUSING»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators). Remove fan clutch. See «FAN CLUTCH»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__fan-clutch). Remove generator drive belt. See «GENERATOR DRIVE BELT 3.0L (M54)»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__generator-drive-belt-30l-m54).
3. If necessary, drain supply tank for power steering pump. Remove with holder and place to one side. Lines on supply tank for power steering pump remain connected.
4. If fitted, remove air hose. (Scheme 24)
5. For version 1, take off cap on connections. Disconnect plug connection (1). (Scheme 25) Remove nut (2) and disconnect wire from battery positive lead.
6. For version 2, disconnect plug connection (1). (Scheme 26) Remove nut (2) and disconnect wire from battery positive lead.
7. On version without idler pulley, remove generator screws in succession while gripping generator firmly. (Scheme 27) Remove generator.
8. On version with idler pulley, remove cover from idler pulley (1). (Scheme 28) Remove screw and remove idler pulley (1). Remove screw and remove generator (2).

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Installation

1. To install, reverse removal procedure. Turning lock of tensioning roller on version with idler pulley must engage in generator groove. (Scheme 29)
2. Tighten wire from battery positive lead to specification. See «TORQUE SPECIFICATIONS»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__torque-specifications).
3. Interrogate fault memory of DME control unit. Clear fault memory.

Scheme 29

GENERATOR 4.4L & 4.6L (M62)

1. Disconnect and cover battery negative lead.
2. Remove generator drive belt. See «GENERATOR DRIVE BELT 4.4L & 4.6L (M62)»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__generator-drive-belt-44l-46l).
3. Remove fan cowl. See «FAN COWL 4.4L & 4.6L (M62)»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators).
4. Open cap on coolant expansion tank. Slacken vent plug on coolant expansion tank. Remove reinforcement plate. Remove underbody paneling. Open drain plug at bottom of radiator. Drain, catch and dispose of coolant observing all appropriate disposal regulations.
5. Remove bolts (1) on generator. (Scheme 30)
6. Remove nut (1). (Scheme 31) Disconnect battery positive wire (2) from generator. Disconnect plug (3). Remove screw (4) and remove roller. Remove screws (5) on generator.
7. Pull out generator towards front. A small amount of coolant will emerge when generator is removed from housing. Catch and dispose of coolant observing all appropriate disposal regulations.

Scheme 30

Scheme 31

1. Replace sealing ring (1) on generator. (Scheme 32)
2. If necessary, replace generator belt pulley. See «GENERATOR BELT PULLEY»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators).
3. To install, reverse removal procedure. Tighten battery positive wire to specification. See «TORQUE SPECIFICATIONS»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__torque-specifications).
4. Open cap and vent plug on coolant expansion tank. (Scheme 33)
5. Turn on ignition. Set heating comtroller to maximum temperature. Set fan to low setting. This opens heating valves and starts auxiliary water pump.
6. Use only recommended BMW coolant (82 14 1 467 704) or equivalent. Very slowly pour coolant into coolant expansion tank up to full level. Close vent plug when bubble-free coolant emerges.
7. Close coolant expansion tank. Allow engine to warm up until thermostat opens.
8. Allow engine to cool down before checking level again. Coolant temperature must not exceed 86°F (30°C). If ambient temperature exceeds 86°F (30°C), allow engine to cool down at least to ambient temperature. Check coolant level. If necessary, top up coolant until liquid reaches marking on coolant expansion tank.
9. Check cooling system for leaks.

Scheme 32

Scheme 33

GENERATOR 4.4L & 4.8L (N62)

Note. A small amount of coolant emerges when generator is removed from housing. Catch and dispose of escaping coolant observing appropriate waste disposal regulations.

Note. There are no vent plugs on radiator or thermostat housing. Cooling system is bled while filling and during subsequent idle operation.

Note. For purposes of clarity, some procedures are shown in figures after component has been removed.

1. Retrieve fault codes. Turn off ignition. Disconnect and cover battery negative terminal.
2. Remove radiator.
3. Remove generator drive belt. See «GENERATOR DRIVE BELT 4.4L (N62)»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__generator-drive-belt-44l-48l).
4. Remove A/C compressor drive belt. See «A/C COMPRESSOR DRIVE BELT 4.4L (N62)»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__ac-compressor-drive-belt-44l-n62).
5. Remove screws on antifriction bearing on left and right of stabilizer bar. Hydraulic lines on oscillating motor remain connected. Do NOT release screws on stabilizer link. Remove stabilizer bar with antifriction bearing from threaded pins and secure from falling down.
6. Release holder from hydraulic lines for power steering. Hydraulic lines on power steering pump remain connected.
7. Remove screws and remove guide pulley (1). (Scheme 34)
8. Unlock plug (1) and remove. (Scheme 35) Unscrew nut (2). Remove battery positive lead from generator (3).
9. Remove screws on generator (3). (Scheme 36) Remove generator out towards front.

Scheme 34

Scheme 35

Scheme 36

1. To install, reverse removal procedure. Replace sealing ring (1) on generator. (Scheme 32) Tighten screws to specification. See «TORQUE SPECIFICATIONS»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__torque-specifications).
2. If necessary, replace generator belt pulley. See «GENERATOR BELT PULLEY»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators).
3. Engine must be cooled down before coolant level is checked. Coolant temperature must not exceed 86°F (30°C). If ambient temperature is above 86°F (30°C), allow engine to cool down to ambient temperature.
4. Turn on ignition. Set blower to low level. Set heating controller to maximum temperature. This ensures that heater valves are fully opened and auxiliary water pump starts up. The auxiliary water pump must deliver coolant in order to ensure full bleeding.
5. Use only recommended BMW coolant (82 14 1 467 704) or equivalent. Perform filling operation slowly. Pour coolant into expansion tank up to MAX mark. (Scheme 37) Do NOT overfill. Start engine and run at idle speed for about one minute with cap open. Add coolant to MAX as necessary. Close cap and run engine up to operating temperature and main thermostat opens. Check cooling circuit and drain plug for leaks.

Scheme 37

1. Depending on generator type, grip shaft with one of the following: Hexagon Socket Multi-Tooth Socket Torx Socket Wrench Remove nut with Special Tool (12 7 110). (Scheme 38)
2. To install, reverse removal procedure. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__torque-specifications).

Scheme 38

GENERATOR DRIVE BELT 3.0L (M54)

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/x5/e53-1999-2003/remont/charging-system/#generators-regulators__fan-clutch).
2. Remove A/C compressor drive belt. See «A/C COMPRESSOR DRIVE BELT»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__ac-compressor-drive-belt-30l-m54).
3. Remove cap from tensioning roller. (Scheme 39)
4. Relieve tension on belt drive. (Scheme 40) 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. (Scheme 41) For version with auxiliary tensioning roller (Scheme 42) Locking device of auxiliary tensioning roller must snap into groove on generator. (Scheme 43)

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

GENERATOR DRIVE BELT 4.4L & 4.6L (M62)

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

1. Remove fan clutch with impeller. See «FAN CLUTCH»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__fan-clutch).
2. Slacken screws (1) and relieve tension on belt drive. (Scheme 44) Remove drive belt.
3. Check drive belt for coolant and oil residue. Replace, if necessary.
4. To install, mount drive belt and check that it is correctly positioned on belt pulleys. (Scheme 45)
5. Pretension adjustable plate at hexagon head (1) up to end of elongated hole (2) and tighten screws (3). (Scheme 46) Screws (3) with liquid cooled generator are M8 strength class 10.9 and tightening torque is 22 ft. lbs. (30 N.m).

Scheme 44

Scheme 45

Scheme 46

GENERATOR DRIVE BELT 4.4L & 4.8L (N62)

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

1. Pretension belt tensioner slowly and carefully with a Torx socket as far as it will go and secure with Special Tool (11 3 340). (Scheme 47) Remove generator drive belt.
2. Check drive belt for coolant and oil residue. Replace, if necessary.
3. To install, reverse removal procedure. Check that belt is correctly positioned on belt pulleys. (Scheme 48)

Scheme 47

Scheme 48

1. Turn off ignition. Remove air-mass sensor. See «AIR-MASS SENSOR 3.0L (M54)»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators).
2. Remove screws. Raise intake filter housing (1) a little. (Scheme 49) Pull intake pipe (2) out of intake hood (3).
3. To install, reverse removal procedure.

Scheme 49

VOLTAGE REGULATOR (BOSCH)

1. Turn off ignition. Retrieve fault codes. Disconnect battery ground wire from generator. Remove generator. See «GENERATOR 3.0L (M54)»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__generator-30l-m54).
2. Release bolts on cover. (Scheme 50)
3. Remove regulator switch. Check contact surfaces of collector rings for wear and recondition if necessary.

Scheme 50

VOLTAGE REGULATOR (VALEO)

1. Turn off ignition. Retrieve fault codes. Disconnect battery ground wire. Remove generator. See «GENERATOR 3.0L (M54)»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__generator-30l-m54).
2. Remove nuts on cover. (Scheme 51)
3. Remove screws. Remove regulator switch. (Scheme 52)
4. Check contact surfaces (1) of collector rings for wear and recondition if necessary. (Scheme 53)

Scheme 51

Scheme 52

Scheme 53

1. Install regulator switch with assembly cap. Hand tighten nuts of regulator switch. Remove assembly cap (1). (Scheme 54)
2. Fit supplied cover cap (2). (Scheme 55) Tighten nuts and ground screw of regulator switch to specification. See «TORQUE SPECIFICATIONS»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__torque-specifications).

Scheme 54

Scheme 55

VOLTAGE REGULATOR 4.4L (N62)

Note. Manufacturer may refer to component as controller switch.

1. Disconnect battery negative lead. Remove generator. See «GENERATOR 4.4L (N62)»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__generator-44l-48l-n62).
2. Carefully insert a screwdriver between cover (1) and threaded pin. (Scheme 56) Lever cover (1) off towards top.
3. Release contact screws (1). (Scheme 57) Unscrew nut (2). Remove regulator (3).
4. Check contact surfaces (1) of slip rings for wear and recondition, if necessary. (Scheme 53)
5. Press in carbon brushes (1) of regulator in direction of arrow. (Scheme 58) Install regulator (2).
6. Insert and tighten contact screws (1). (Scheme 57) Insert nut (2) and tighten.
7. Install generator. See «GENERATOR 4.4L (N62)»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__generator-44l-48l-n62).
8. Perform generator test. See «GENERATOR & REGULATOR SWITCH»(/bmw/x5/e53-1999-2003/remont/charging-system/#generators-regulators__generator-regulator-switch) under TESTING.

Scheme 56

Scheme 57

Scheme 58

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Scheme 59

See also:
• GENERATOR OSCILLOGRAMS
• GENERATOR 3.0L (M54)
• GENERATOR 4.4L & 4.6L (M62)
• GENERATOR 4.4L (N62)
• VOLTAGE REGULATOR (BOSCH)
• VOLTAGE REGULATOR (VALEO)
• VOLTAGE REGULATOR 4.4L (N62)
• GENERATOR DRIVE BELT 4.4L (N62)
• TORQUE SPECIFICATIONS
• FAN CLUTCH
• GENERATOR DRIVE BELT 3.0L (M54)
• GENERATOR DRIVE BELT 4.4L & 4.6L (M62)
• A/C COMPRESSOR DRIVE BELT 4.4L (N62)
• A/C COMPRESSOR DRIVE BELT
• GENERATOR & REGULATOR SWITCH