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Generators & Regulators Land Rover Range Rover III

Charging System 11 illustrations ~1199 words

BATTERY CHARGE INDICATOR

The battery charge indicator warning lamp located in instrument cluster, is controlled by the ECM and the instrument pack software. The battery charge indicator illuminates in a Red color with the ignition in position II and the engine not running. If the lamp remains illuminated when the engine is started or illuminates when driving, the generator charge output has failed.

The generator charges the battery when the engine is running and increases its output as demand on the battery increases. The generator is located at the front left side of the engine.

The generator has an output of 90/150 Amps and is manufactured by Bosch.

A polyvee belt drives the generator pulley, which in turn is driven from the engine crankshaft pulley.

BATTERY DISCONNECT & RECONNECT

CAUTIONNever disconnect the battery with the ignition switched on. To prevent damage to the navigation computer hardware, a waiting period of 2 minutes must elapse after the ignition is switched off before the battery leads are disconnected. To prevent damage to electrical components, always disconnect the battery when working on the vehicle's electrical system. The ground lead must be disconnected first and reconnected last. Always ensure that battery leads are routed correctly and are not close to any potential chafing points.

It is imperative that the key is removed from the ignition before disconnecting the battery. A time of 2 minutes must also elapse before disconnection. Failure to do so could result in

  1. Navigation computer hardware damage.
  2. Incorrect fuel gauge reading.

Before disconnecting the battery, disable the alarm system and switch off all electrical equipment. If the radio is to be serviced, ensure the security code has been deactivated.

Open hood. Disconnect ground lead. Reconnect ground lead.

DRIVE BELT TENSION

No adjustment is necessary. Ancillary drive belt tension is controlled by an automatic belt tensioner. Check ancillary drive belt for signs of splits, fraying, oil contamination and wear. Replace as necessary.

PRELIMINARY CHARGING SYSTEM CHECK

Ensure battery is in good condition and has a circuit voltage of at least 12.3-12.6 volts. Ensure battery connections are clean and tight. Ensure battery charging area is well ventilated and that there are no open flames or sparks. Check condition of ancillary drive belt. Ensure generator connections are clean and tight. Check for parasitic drain on battery.

CHARGE WARNING INDICATOR LIGHT

Manufacturer does not provide testing information.

BENCH TESTING

Note. Bench testing information is not available from manufacturer.

Removal

  1. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See «BATTERY»(/land-rover/range-rover/iii-2002-2005/remont/charging-system/#generators-regulators__battery-disconnect-reconnect) under SERVICE PRECAUTIONS. Disconnect battery ground lead.
  2. Loosen 2 ancillary drive belt tensioner bolts. (Scheme 1)
  3. Using a 17 mm wrench, rotate belt tensioner fully clockwise to release tension on ancillary drive belt. (Scheme 2)
  4. Hold tensioner in retracted position and tighten tensioner clamping bolt. Release ancillary drive belt from tensioner pulley. (Scheme 3)
  5. Release and remove ancillary drive belt from remaining pulleys. (Scheme 4)
  6. Slowly rotate fan by hand while positioning ancillary drive belt over fan blades between fan and fan cowl to remove belt. (Scheme 5)

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Installation

  1. Check that ancillary drive belt pulleys are damage free.
  2. Install ancillary drive belt over cooling fan assembly.
  3. Install ancillary drive belt to all pulleys except tensioner pulley.
  4. Install ancillary drive belt to tensioner pulley.
  5. Ensure ancillary drive belt is aligned to all pulleys.
  6. Undo tensioner clamping bolt to release tensioner.
  7. Using a 17 mm wrench, rotate belt tensioner fully counter clockwise to tension ancillary drive belt.
  8. Hold tensioner in the tensioned position and tighten tensioner bolts to specifications. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/charging-system/#generators-regulators__torque-specifications) .
  9. Connect battery ground lead.
  1. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See «BATTERY DISCONNECT & RECONNECT»(/land-rover/range-rover/iii-2002-2005/remont/charging-system/#generators-regulators__battery-disconnect-reconnect).
  2. Raise vehicle and support.
  3. Disconnect battery ground lead.
  4. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/iii-2002-2005/remont/accessory-drive-belts/#specifications-drive-belt-routing__draining-refilling-cooling-system) under SPECIFICATION & DRIVE BELT ROUTING - 4.4L article in ENGINE.
  5. Remove viscous cooling fan. See «VISCOUS COOLING FAN»(/land-rover/range-rover/iii-2002-2005/remont/cooling-fan/#engine-cooling) under REMOVAL & INSTALLATION in COOLING SYSTEM (MECHANICAL) article.
  6. Remove ancillary drive belt tensioner. See «TENSIONER (ANCILLARY DRIVE BELT)»(/land-rover/range-rover/iii-2002-2005/remont/charging-system/#generators-regulators).
  7. Release clip and disconnect radiator top hose from radiator. (Scheme 6)
  8. Release clips and disconnect radiator top hose from coolant pump and generator.
  9. Position hose aside.
  10. Disconnect pipe from charcoal canister purge control valve, release valve from bracket and position valve aside. (Scheme 7)
  11. Release battery lead from securing clip on engine timing cover.
  12. Disconnect harness connector from generator. (Scheme 8)
  13. Remove nut and disconnect battery cable from generator. (Scheme 9)
  14. Release harness connector from securing clip on generator. Remove 6 bolts securing generator, remove harness securing clip and remove generator. Discard generator "O"ring. (Scheme 10)

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10
  1. Clean generator and engine timing gear cover mating face.
  2. Lubricate and install NEW "O" ring to generator.
  3. Position generator into casing, install bolts securing generator and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/charging-system/#generators-regulators__torque-specifications) .
  4. Connect battery cable to generator and tighten nut securing battery cable to generator to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/charging-system/#generators-regulators__torque-specifications) .
  5. Secure battery cable into securing clip on engine timing cover.
  6. Connect harness connector to generator.
  7. Secure generator harness into securing clip on generator.
  8. Install charcoal canister purge control valve and connect pipe.
  9. Connect radiator top hose to coolant pump and generator and secure clips.
  10. Connect top hose to radiator and secure with clip.
  11. Install ancillary drive belt tensioner.
  12. Install viscous coupling.
  13. Connect battery ground lead.
  14. Fill cooling system.
  1. Disconnect battery ground lead.
  2. Remove fan cowl.
  3. Loosen 2 ancillary drive belt tensioner bolts. (Scheme 1)
  4. Using a 17 mm wrench, rotate belt tensioner fully clockwise to release tension on ancillary drive belt. (Scheme 2)
  5. Hold tensioner in retracted position and tighten tensioner clamping bolt. (Scheme 3)
  6. Release ancillary drive belt from tensioner pulley. (Scheme 4)
  7. Remove nut securing tensioner to tensioner adjusting bracket. (Scheme 5)
  8. Remove 2 bolts securing ancillary drive belt tensioner to lower timing gear cover.
  9. Remove dust cap from ancillary drive belt tensioner idler pulley and remove Torx bolt securing ancillary drive belt tensioner idler pulley.
  10. Remove ancillary drive belt tensioner assembly.
  11. Remove bolt and tensioner from pulley mounting.
  12. Remove tensioner from tensioner adjusting bracket.
  1. Install tensioner to tensioner adjusting bracket. Install securing nut but DO NOT fully tighten at this stage.
  2. Install tensioner to pulley mounting and tighten bolt. Tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/charging-system/#generators-regulators__torque-specifications).
  3. Install pulley and tensioner mounting to timing gear cover and tighten bolt.
  4. Install dust cap to tensioner pulley.
  5. Install tensioner to upper timing gear cover, install 2 securing bolts but do not tighten at this stage.
  6. Using a 17 mm wrench, rotate belt tensioner fully clockwise.
  7. Hold tensioner in retracted position and tighten tensioner clamping bolt.
  8. Install ancillary drive belt to all pulleys except tensioner pulley. (Scheme 11)
  9. Install ancillary drive belt to tensioner pulley.
  10. Ensure ancillary drive belt is aligned to all pulleys. Loosen tensioner clamping bolt to release tensioner.
  11. Using a 17 mm wrench, rotate belt tensioner fully counterclockwise to tension ancillary drive belt.
  12. Hold tensioner in the tensioned position and tighten tensioner bolts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/charging-system/#generators-regulators__torque-specifications).
  13. Tighten tensioner to tensioner adjusting bracket securing nut. Tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/iii-2002-2005/remont/charging-system/#generators-regulators__torque-specifications).
  14. Install fan cowl.
  15. Connect battery ground lead.

Scheme 11

Scheme 11
Scheme 11

OVERHAUL

Note. Information is not available from manufacturer.

GENERATOR SPECIFICATIONS

ApplicationSpecification
Range Rover90-150 amps

GENERATOR SPECIFICATIONS

TORQUE SPECIFICATIONS

ApplicationsFt. Lbs. (N.m)
Generator-To-Battery Cable10 (13)
Generator-To-Cases10 (13)
Tensioner Bolts-To-Timing Gear Cover22 (30)
Tensioner Pulley Bolt37 (50)

TORQUE SPECIFICATIONS

WIRING DIAGRAMS

For appropriate wiring diagram

  1. For 2003 models, see «STARTING/CHARGING»(ref-159346-S04768738812003120100000) in SYSTEM WIRING DIAGRAMS - RANGE ROVER article in ELECTRICAL.
  2. For 2004 models, see «STARTING/CHARGING»(ref-166687-S35290247702004092700000) in SYSTEM WIRING DIAGRAMS - RANGE ROVER article in ELECTRICAL.