LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Generator and Regulator -
General SpecificationItemSpecification
Generator - 3.2L Petrol:
Make/t ypeBos chOut put90/150 amps @25° C
Volt age cont rolExternal ly controlled by EMS us ing LIN prot ocol t o communicat e.
Volt age s et point regulat ionControlled by software res i dent i n EMSGenerator - 2.2L Diesel:
Make/t ypeBos ch
Out put - St andard90/150 amps @25° COut put - O pt ional105/180 amps @ 25° C
Volt age Cont rolExternal ly controlled by EMS us ing LIN prot ocol t o communicat e.
Volt age Regul ati onControlled by software res i dent i n EMS
Torque Specifications
DescriptionNmlb-ftBatt ery harnes s connect ion nut - 3.2L Pet rol129
batt ery cable to the generat or nut - 2.2L Dies el2418
Drive belt i dler pul ley - 2.2L Dies el4835Generat or coupling7555
Generat or bolt s - 3.2L Pet rol2418
Generat or bolt s - 2.2L Dies el4835

Publi s hed: 11-May-2011
Generator and Regulator - GeneratorI6 3.2L Petrol
Des cript ion and Operat ion
COMPONENT LOCATION
OVERVIEW
The generator us ed on t he Si6 obt ai ns a direct drive from a s haft powered by the cranks haft; a coupli ng unit at taches thegenerator t o t he shaft. This di rect dri ve arrangement improves the generat or's durabi li ty by prevent ing s ide-loadings,caus ed by t he t ens ion of a dri ve bel t, acti ng on t he generator's rot or bearing.
The generator has an output of 90/150 amps , and compris es a:
s tat or,rot or,rect ifi er pack, andregulat or
The s tat or cons is ts of a fl at core pack into which t he s tat or wi res are pres s ed. The rotor compri ses a fi eld wi nding, woundaround an i ron core and mount ed on a shaft. The rotor is hous ed wi thin the s t ator and is mount ed on beari ngs to provides mooth running and s upport.
The rect ifi er convert s t he Alt ernati ng Current (AC) produced i n t he s tat or coil s i nto Di rect Current (DC), as requi red by thevehi cl e elect rical s ys t em. The recti fi er compris es 6 s emi-conductor diodes mounted on a heat si nk t hat di ss ipat es theres ult ant heat .
The regulat or provides a control led variable volt age output from the generat or. Two electrical terminals are provi ded on theouter casi ng of the generat or. One t ermi nal s uppli es the rect ified and regul ated DC current from the generat or vi a a l argediamet er cable to the bat tery pos i ti ve terminal. The s econd terminal provides t he Local Int erconnect Network (LIN) busconnecti on bet ween t he regulat or and the Engine Cont rol Modul e (ECM).
The regulat or connect s via the LIN bus t o t he ECM, and the ECM als o connects vi a t he high s peed Cont rol ler Area Net work(CAN) bus t o t he Central Junct ion Box (CJB). The CJB cont ains s oft ware maps that provi de a mat hemat ical model ofbatt ery el ect rolyt e t emperature, and cons tantl y receives i nformat ion from t he ECM regarding t he act ual bat tery volt age.Based on the informati on received, the CJB t hen communi cat es via the hi gh speed CAN bus to t he ECM a predict ed out putvolt age that is required from t he regulat or to effecti vel y charge t he batt ery.
A corresponding mes s age is then communicated by the ECM to the regul ator via the LIN bus , to meet t he output volt agedetermined by t he CJB. Thi s cont rol cycle is repeat ed under a cl osed-loop condi ti on.
The LIN bus is al so used t o communicat e a faul t in the wi ri ng or the connect ions from the generat or to t he ECM. A faultcode wil l be generat ed and s tored in the ECM and if neces s ary, the charge warning i ndicat or lamp wil l be dis played in t heins t rument clus ter aft er a s hort delay. During engi ne st art ing the charge warning i ndi cat or lamp i s il lumi nat ed i n t heins t rument clus ter when t he ignit ion i s energized, and wil l ext inguis h when t he engine s tarts and the ECM det ect s agenerator output volt age.

Publi s hed: 11-May-2011
Generator and Regulator - GeneratorTD4 2.2L Diesel
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription
1-Local Interconnect Net work (LIN) bus connect ion2-Bat tery pos i ti ve connect ion
3-Generat or
OVERVIEW
A s i ngl e s elf-exci ti ng generator is locat ed at t he front of t he engine on t he Left -Hand (LH) s ide of t he cyl inder bl ock. Twogenerators are avail abl e for t he TD4 engine, dependent on vehi cl e s peci fi cat ion. The generat ors are rated at 90/150 ampsand 115/180 amps respecti vel y. The l arger rat ed generator is us ed on cold cl imat e market vehicles ins tall ed wit h a heat edfront winds hi eld and el ect ri c boos t er heat er.For addit ional informat ion, refer t o: Electric Boos ter Heater (412-02B Auxi li ary Cl imat e Control , Descripti on and Operat ion).
The generator pull ey incorporates a one-way clut ch that reduces Nois e, Vi brat ion and Harshnes s (NVH), and improves theli fe of t he acces s ory drive belt . The one-way clut ch al lows t he belt t o drive t he pul ley wi thout s li p occurring, but prevent st he generat or from driving t he belt during t rans ients in engine s peed ('belt whip') due to the hi gh rot at ional inert ia of thegenerator int ernal components .
The generator compri ses t he fol lowi ng major component s:
Stat orRotorRect ifier packRegul ator.
The s tat or cons is ts of a fl at core pack into which t he s tat or wi res are pres s ed.
The rot or compris es a fiel d winding, wound around an i ron core and mounted on a s haft. The rotor is hous ed wi thin thes tat or and mount ed on beari ngs to provi de s mooth running and s upport, due t o t he s ide l oadi ng appl ied by t he dri ve beltt ens ion.
The rect ifi er compris es 6 s emi -conductor di odes mount ed on a heat s ink. The heat s ink di ss i pat es t he res ult ant heatcreated in t he electrical convers ion proces s . The recti fi er converts the Al ternat ing Current (AC) produced i n the st ator coil sint o Di rect Current (DC) that is required by the vehicl e electrical sys tem.
The regulat or provides a control led variable volt age output from the generat or. Two electrical terminals are provi ded on theouter casi ng of the generat or. One t ermi nal s uppli es the rect ified and regul ated DC current from the generat or, via a largediamet er cable to the bat tery pos i ti ve terminal. The s econd terminal provides t he LIN bus connect ion bet ween theregulat or and the Engine Cont rol Modul e (ECM).

The regulat or is connect ed vi a t he LIN bus to the ECM, t he ECM i s als o connect ed vi a t he high s peed Control ler AreaNetwork (CAN) bus t o t he Central Junct ion Box (CJB). The CJB cont ains s oft ware maps t hat provi de a mat hemati cal modelof bat t ery elect rolyt e t emperature, and const antl y receives informat ion from t he ECM regardi ng t he act ual bat tery vol tage.Based on the informati on received, the CJB t hen communi cat es via the hi gh speed CAN bus to t he ECM a predict ed out putvolt age that is required from t he regulat or to effecti vel y charge t he batt ery. A corresponding mes s age is t hencommunicated by t he ECM t o t he regul at or via t he LIN bus, t o meet t he output volt age det ermi ned by the CJB. This controlcycle is repeat ed under a cl osed-loop condi ti on.
The LIN bus is al so used t o communicat e a mechani cal failure, or fault i n the wiring and connecti ons from t he generator t ot he ECM. A Diagnost ic Troubl e Code (DTC) is s t ored in the ECM and if neces s ary, t he charge warning indicator lamp isil lumi nat ed i n the ins trument cl us t er aft er a short del ay.
Duri ng engi ne s tarti ng the charge warning i ndi cat or lamp is i ll uminated i n t he ins t rument clus ter when t he ignit ion i senergized, and is exti ngui s hed when the engine s t art s and t he ECM detects a generator output volt age.
Stop/Start Vehicles - From 2010 MY
Due t o t he addi ti onal l oads a hi gher rated 180 amp generator is us ed on St op/St art vehi cles .For addit ional informat ion, refer t o: Starti ng Sys t em (303-06C Starti ng Syst em - TD4 2.2L Di es el, Vehicles Bui lt From:01-03-2009, Descripti on and Operat ion).
CONTROL DIAGRAM
• NOTE: D = Hi gh s peed CAN bus ; O = LIN bus
ItemPart NumberDescription
1-CJB2-Generator
3-ECM
4-Ins t rument clus ter

Publi s hed: 11-May-2011
Generator and Regulator - Generator
Diagnosi s and Tes ti ng
For addit ional informat ion.REFER to: Chargi ng Sys t em (414-00, Diagnos is and Tes t ing).

Publi s hed: 11-May-2011
Generator and Regulator - GeneratorI6 3.2L Petrol
Removal and Inst all ati on
Special T ool(s)
303-1255Inst all er, Generator dowels
303-1278Al igner, Timing Cover
303-502Socket , Flywheel Bolt
Removal
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
2.
Remove t he int ake mani fol d.
Refer t o: Int ake Mani fol d (303-01A Engi ne - I6 3.2L Petrol, Removaland Inst all at ion).
3.
Di sconnect t he generat or harness .4.
Remove t he generat or.5.

6. CAUTION: Mark the component s t o aid ins tal lati on.
Remove t he coupli ng.
6. 7.
NOTE: Do not dis ass embl e further if t he component
i s removed for acces s onl y.
Remove t he dowel s .
7. Remove t he generat or coupli ng.
Speci al Tool (s ): 303-1278 ,
303-502 8.
Installation Inst all t he generat or coupli ng.
T orque: 75 Nm 1.
Inst all t he locati ng dowel s fl ush wit h t he generator casi ng.
2.
3. NOTE: Make s ure t hat the i nst all at ion marks are aligned.
Inst all t he coupli ng.
3.
Locat e t he generator and ins t al l and li ght ly t ight en the upper bolt s.
4.

Us ing t he s peci al t ool, i ns t all the dowel s to align the
generator.
Speci al Tool (s ): 303-1255 5.
Tight en the generat or bol ts .
T orque: 24 Nm 6.
Connect t he generator harnes s and ti ght en t he nut.
T orque: 12 Nm 7.
Inst all t he int ake mani fol d.
Refer t o: Int ake Mani fol d (303-01A Engi ne - I6 3.2L Petrol, Removal
and Inst all at ion).
8.
Connect t he batt ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
9.

Publi s hed: 11-May-2011
Generator and Regulator - GeneratorTD4 2.2L Diesel
Removal and Inst all ati on
Removal
Remove t he cover and dis connect the bat tery ground cabl e.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
1.
Remove t he fuel fi lt er.
Refer t o: Fuel Fil ter (310-01B Fuel Tank and Lines - TD4 2.2L Dies el ,
Removal and Ins tall ati on).
2.
3. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Rais e and s upport t he vehi cl e.
3.
Remove t he engi ne undershi eld.
Refer t o: Engi ne Unders hi eld (501-02 Front End Body Panel s ,
Removal and Ins tall ati on).
4.
Remove t he acces sory dri ve bel t.
Refer t o: Acces sory Dri ve Belt (303-05B Acces sory Drive - TD4 2.2L
Di es el, Removal and Ins tal lat ion).
5. 6.
7.

8.
9.
10.
Releas e t he power s t eering pump.
11.