engine LAND ROVER FRELANDER 2 2006 Repair Manual

Publ is hed: 05-Dec-2011
Battery and Charging System - General Information - Charging System
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the chargi ng s ys t em, refer t o t he rel evant Des cript ion and Operat ion secti on in the workshopmanual. REFER to:
Bat t ery Care (414-00, Des cript ion and Operat ion),Bat t ery and Cables (414-01, Des cri pti on and Operati on),Generator - ID4 2.4L Di esel (414-02, Des cri pt ion and Operati on).
Inspection and Verification
CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is NO T acceptabl e. Subs ti tut ion of cont rol modules doesnot guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he vehi cl e being t est ed and/or t he donorvehi cl e.
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.2.
• NOTE: Check the vehicle bat tery condi ti on and st ate of charge before condemning any of the chargi ng s ys t emcomponents . For addi ti onal i nformat ion, refer to the bat tery care manual.
For a compl ete lis t of all di agnos ti c troubl e codes that coul d be l ogged on t his vehicle, pleas e refer to s ect ion 100-00.REFER to: (100-00)
Diagnos t ic Troubl e Code (DTC) Index - DTC: Engine Cont rol Module (PCM) (Des cri pt ion and Operati on),Diagnos t ic Troubl e Code (DTC) Index - DTC: Ins trument Clus ter (IPC) (Des cri pti on and Operati on).
Visual Inspection
MechanicalElectricalGenerat orDrive beltDrive belt t ensi onerGenerat or pull eyCheck the s ecurit y of t he generat or fi xings
Generat orBat teryMega-fus eEngine/generat or ground connecti onHarness (s)El ect ri cal connector(s )Engine Cont rol Module (ECM)Cent ral juncti on box (Freel ander 2 onl y)
3. If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) beforeproceeding t o t he next s t ep3.
4. If t he caus e is not vis ually evi dent , check for Di agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
DTC Index
• NOTE: If the control modul e or a component i s s us pect and the vehicle remains under manufacturer warrant y, refer t o theW arranty Pol icy and Procedures manual (s ect ion B1.2), or determine i f any pri or approval programme is in operat ion, pri ort o the ins tall ati on of a new module/component.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only fi ve digit codes . Mat ch the five di git s from t hes can tool to the firs t fi ve di git s of the seven digi t code l is ted to ident ify t he faul t (t he las t t wo digi ts gi ve ext rainformat ion read by the manufact urer-approved diagnost ic s ys tem).
• NOTE: W hen performing el ect ri cal volt age or resi s tance tes t s, al ways us e a digit al mult imet er (DMM) accurate to threedeci mal places , and wi th an up-to-date cali brat ion cert ificate. W hen t es ti ng res is t ance, always take t he res i st ance of t heDMM leads int o account.
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi ng pinpoint t es t s.
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is not present , an int ermi tt ent concern maybe t he caus e. Always check for loose connect ions and corroded terminals .
SymptomPossible CauseAction
Charge warning l amp does noti llumi nateW arning l amp/circui t -faul tGenerat or - internalfaul tCAN Bus - ci rcuit faul tEngine control modul e- i nternal faul t
Check t he warni ng lamp functi on wit h t heignit ion on and the engine offRepai r the ci rcuit as neces s aryCheck for DTCs indicati ng a generator, CAN orengi ne cont rol module fault
Charge warning l amp s tayson/bat tery dis chargesAcces s ory drive belt -faul tGenerat or pul leys li ppi ng on s haftGenerat or - internal
Check t he batt ery and generat or cablesRefer t o the el ect ri cal guidesCheck for DTCs indicati ng a generator faul tCheck t he acces s ory drive belt condi ti on andtens ion

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2
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2
3
4
5
6
1
1
SymptomPossible CauseAction
faul tBat tery cable - faultCAN Bus - ci rcuit faul tEngine control modul ei nt ernal faul tCentral junct ion box
Check t hat the pul ley does not rotat eindependentl y of the generat orCheck for DTCs indicati ng a CAN, cent ral junct ionbox or engi ne cont rol module fault
Charge warning l amp int ermi tt entAcces s ory drive belts li ppi ngBat tery cable - faultGenerat or - ci rcuit faul tGenerat or - internalfaul tCAN Bus - ci rcuit faul t
• NOTE: Us e of a power pack or boost charger may bringthe warning l amp on unt il dis connected
Check t he acces s ory drive belt condi ti on andtens ionCheck t he batt ery and generat or cables refer t othe el ect ri cal guidesCheck for DTCs indicati ng a generator or CANcircuit fault
Batt ery di s charges wi thout t hecharge warni ng lamp s taying onBat tery - faultBat tery qui escent drainIntermit tent generator- faul t
Check t he batt ery condit ionCheck for bat t ery quies cent drai nCheck for DTCs indicati ng a generator faul tIf no ot her reas on for dis charge can be found,check t he circuit . Refer t o t he elect rical guides
Nois e (mechani cal )Acces s ory drive belts li ppi ngCheck t he acces s ory drive belt condi ti on andtens ionDis connect the access ory drive bel t and checkthat t he generator rot ates freel y
Test Procedure
PINPOINT TEST A : BOSCH NON-BMS GENERATOR DIAGNOSTIC FLOW CHART
T ESTCONDIT IONSDET AILS/RESULT S/ACT IONS
A1: MIDT RONICS BAT T ERY T EST• NOTE: The batt ery must be full y charged and any batt ery defect s recti fi ed before cont inuing wi th generat or diagnos i s
• NOTE: The volt meter mus t dis play readings to three deci mal pl aces (i.e. 0.001V)
• NOTE: Ignition on is pos it ion 2 on a keyed ignit ion s yst em• NOTE: Ignition on is t wo s hort pres s es of the st art but ton (power mode 6) wit h keyl ess ignit ion s ys tem
Us ing a Midt ronics hand held tes ter or t he Midt ronics GR-1 diagnost ic charger, carry out t he"Midt ronics batt ery tes t" as det ailed in t he batt ery care manual .REFER t o: Bat tery Care (414-00, Descripti on and Operat ion).
Record bat tery diagnos t ic resul t on the provi ded form
Does t he bat t ery pas s the "Mi dtroni cs bat tery t es t "?YesGO to B1.NoRecti fy any bat tery defect s before cont inuing wit h generator diagnosi s GO to Pi npoi nt Tes t B.
PINPOINT TEST B : BOSCH NON-BMS GENERATOR DIAGNOSTIC FLOW CHART
T ESTCO NDIT IONSDET AILS/RESULT S/ACT IONS
B1: GENERAT OR OUT PUT• NOTE: Freel ander 2 = The heat ed rear s creen i s ti med t o operat e for 12 minutes
• NOTE: Defender = The heat ed rear s creen is t imed to operate for 8 mi nutes
Connect a volt meter t o t he vehi cl e batt ery
Swit ch ignit ion s t ate t o on (engine off)
Turn off al l electrical l oads e.g. (bl ower, radio, i nteri or li ght s etc.)
Start the engine, s wit ch on t he heat ed rear s creen
Ens ure the heat ed rear s creen is on (s ee not e above) and t hat t he air condit ioning s ys tem is off.
W ait 90 seconds
Record the bat tery volt age (V1) shown on the mul ti meter
Does bat tery volt age (V1) = 14.8 volts or greater at i dle?YesIns t al l a new generat or. Refer t o the warrant y poli cy and procedures manual, or determine if anypri or approval programme is in operat ion, pri or t o t he ins t al lat ion of a new modul e/componentNoGO t o B2.
B2: BAT T ERY VO LT AGE AT IDLE
Us ing batt ery vol tage readi ng (V1)
Does bat tery volt age (V1) = 13 volts or greater at idl e (But less than 14.8 volts)?YesGO t o B3.NoGO t o Pi npoint Tes t C.
B3: BAT T ERY WARNING LAMP
The bat t ery volt age is (V1) = 13 volts or greater at idle (but less than 14.8 volts)

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2
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Is the bat tery warning lamp i ll uminated?YesGO t o Pi npoint Tes t C.NoThe generat or output is wit hi n t he expected range, Do not replace the generator. If cus tomerconcern i s s ti ll evident cont act dealer t echnical support
PINPOINT TEST C : BOSCH NON-BMS G ENERATOR DIAG NOSTIC FLOW CHART
T ESTCONDIT IONSDET AILS/RESULT S/ACT IONS
C1: CIRCUIT CHECKS
• NOTE: Freel ander 2 = Charge warni ng lamp is driven by t he cent ral juncti on box (from t he powert rain cont rol module) tot he ins trument panel clus ter via the CAN bus
• NOTE: Defender = Charge warning lamp i s dri ven by the powertrain control modul e t o the ins trument panel cl ust er viat he CAN busFreelander 2 = Refer t o t he elect rical circui t diagrams and check t he (LIN) ci rcuit bet ween thegenerat or and the engine control modul e for s hort ci rcuit t o ground, short ci rcuit to power, openci rcuit , hi gh res i st ance fault s
Defender = Refer to the el ect ri cal circuit di agrams and check the (D+ and ALTMON) circui ts bet weenthe generat or and t he engine control modul e for s hort circui t to ground, s hort circui t t o power, openci rcuit , hi gh res i st ance fault s
Are any circui t fault s evident?YesRepair t he circui t as required GO t o Pi npoi nt Tes t B.NoGO t o Pinpoint Tes t D.
PINPOINT TEST D : BOSCH NON-BMS GENERATOR DIAGNOSTIC FLOW CHART
T ESTCO NDIT IONSDET AILS/RESULT S/ACT IONS
D1: CIRCUIT CHECKS 1
• NOTE: Freel ander 2 = The heat ed rear s creen i s ti med t o operat e for 12 minutes• NOTE: Defender = The heat ed rear s creen is t imed to operate for 8 mi nutes
Connect a volt meter t o t he vehi cl e batt ery
Swit ch ignit ion s t at e t o on (engine off)
Turn off al l elect rical l oads e.g. (bl ower, radio, i nt eri or light s etc.)
Start the engine, s wit ch on the heat ed rear s creen
Ens ure the heated rear s creen is on (s ee note above) and t hat t he air condi ti oning s yst em is off.
Vol tage meas urement
Meas ure the volt age drop bet ween the generat or body and bat tery negat ive t ermi nal and recordthe value (V2)
Does t he volt age drop value (V2) = less than 0.3 Volts ?YesGO t o D2.NoSwit ch off engi ne. Ci rcuit check. Refer t o t he electrical ci rcuit diagrams, check the generator bodyand battery negative cables for loos e or corroded connecti ons . Repair any circuit fault s, retes t t hegenerat or GO t o Pi npoint Tes t B.D2: CIRCUIT CHECKS 2
Vol tage meas urement s
Meas ure the volt age drop bet ween the generat or B+ terminal and battery positive terminal andrecord value (V3)
Does t he volt age drop value (V3) = less than 0.3 Volts ?YesIns tal l a new generator. Refer to the warrant y policy and procedures manual, or determine if anyprior approval programme is i n operat ion, prior t o t he ins t al lat ion of a new modul e/componentNoSwit ch off engi ne. Ci rcuit check. Refer t o t he electrical ci rcuit diagrams check t he generator B+terminal and positive battery cables for l oose or corroded connect ions . Repai r any ci rcuit faul ts ,ret es t t he generator GO to Pi npoi nt Tes t B.

Publi s hed: 11-May-2011
Battery, Mounting and Cables -
General SpecificationItemSpecification
Battery - All models:
TypeExide H7Capaci ty80Ah/700CCA
Res erve capacit y125 minutes
Battery Disconnect/C onnect
CAUTION: The vehicle s t atus and batt ery condit ion mus t be es t abl is hed before att empti ng bat t erydis connect/connect . Reference mus t be t hen made t o t he fol lowing table to es t abl is h t he rel evant procedure t o befol lowed.
• NOTE: Vehicles fit ted wit h a fuel fired boos t er heat er will requi re a 5 mi nute wait before tel es t art funct ion wi ll operate.Cycl e t he ignit ion off->on->off. W ai t 5 mi nutes t o all ow fuel fired boos t er heat er to s t ore vehicle confi gurati onparamet ers .
Vehicle statusBattery chargedBattery discharged
ProcedureProcedure
Engine runni ng1Vehicle powered down, l ocked and alarmed23
Vehicle unl ocked45
Procedure 1
Disconnect batteryConnect battery1. Apply parki ng brake oralt ernat ively, chock wheels1. Ens ure that all el ect ri cal loads are s wit ched O FF
2. Swit ch off i gni ti on andremove the remote cont rol.2. Connect bat t ery l eads - GROUND lead l ast
3. W ai t 2 mi nut es for enginemanagement sys tem t o 'powerdown'
3. Swit ch on ignit ion
4. Open t he hood4. Reset radi o s tat ion preset but tons .
5. Dis connect batt ery - GROUNDl ead firs t5. Reset clock
6. Reset elect ric window one-t ouch facili ty. Power window up t o hard s top, rel eas es wit ch, reapply and hol d for 1 s econd (relay i n door wil l cl ick). Lower window t o s top,reapply and hold for one s econd. One t ouch s hould now work
Procedure 2
Disconnect batteryConnect battery
1. Unlock t he vehi cl e and dis armt he alarm us ing t he remotecont rol
1. Ensure t hat al l el ect ri cal l oads are s wit ched OFF
2. Apply parki ng brake oralt ernat ively, chock wheels2. Connect batt ery l eads - GROUND l ead las t
3. W ai t 2 mi nut es for enginemanagement sys tem t o 'powerdown'
3. Swit ch on i gni ti on
4. Open t he hood4. Res et radio s t ati on pres et but tons .
5. Dis connect batt ery - GROUNDl ead firs t5. Res et cl ock
6. Res et el ect ri c window one-touch facil it y. Power window up to hard s top, rel eases wit ch, reappl y and hold for 1 s econd (rel ay in door wil l cl ick). Lower window t o s top,reapply and hol d for one s econd. One t ouch should now work
• NOTE: 1. Disconnect battery - If the remot e cont rol is not funct ioning, it will be necess ary to manual ly unlock thevehi cl e us ing t he key.
Procedure 3
Disconnect batteryConnect battery1. Unlock t he vehi cl e from the LH frontdoor us i ng the key1. Ens ure t hat al l electrical l oads are s wi tched OFF
2. Enter t he vehi cl e, and dock t heremote control to si lence the al arm.2. Connect batt ery leads - GROUND l ead las t
3. Remove t he remot e cont rol and wai t2 minutes for engi ne managements yst em to 'power down'
3. Swi tch on i gni ti on
4. Open t he hood4. Res et radio st ati on pres et but t ons .
5. Dis connect batt ery - GROUND leadfirst5. Res et cl ock
6. Res et el ect ri c wi ndow one-touch facil it y. Power wi ndow up to hard s t op,release s wit ch, reapply and hol d for 1 second (relay i n door wil l cl ick). Lowerwi ndow to s top, reapply and hold for one s econd. One t ouch s hould now work
• NOTE: 1. Connect battery - If there is ins uffi cient capacit y in the bat tery to di s arm the al arm, t he alarm may sound onreconnect ion of t he bat t ery - St ep 2 wi ll dis arm t he alarm
Procedure 4
Disconnect batteryConnect battery

Publi s hed: 11-May-2011
Battery, Mounting and Cables - Battery and Cables
Des cript ion and Operat ion
COMPONENT LOCATION
• NOTE: TD4 s hown, i6 s imil ar
ItemPart NumberDescription1-Batt ery
2-Central Junct ion Box (CJB)
3-Auxili ary Junct ion Box (AJB)4-Batt ery Junct ion Box (BJB)
5-Starter mot or
6-Generator
OVERVIEW
The batt ery i s located behind a cover on t he Left Hand (LH) si de of the engine compart ment . The bat tery s it s in a t ray andis secured i n pos it ion wi th a clamp pl at e and bolt as s embly. The batt ery s upplies elect ri cal power to the s t art er motor,generator and BJB.
The BJB is mount ed adjacent t he LH front s us pens ion t urret. The BJB cont ains fusi ble l inks , bl ade and J-case fus es, andrel ays to di st ribute el ect ri cal power to various vehicle s ys tems and junct ion boxes .

• NOTE: The fus i bl e l inks are mount ed on t he inboard s i de of the BJB behind a series of removable covers .
The CJB is mount ed behind t he glovebox and recei ves it s main power s uppl y from the BJB. In addi ti on to cont aining bl adefus es , the CJB i s t he main controll er for a number of vehicle s ys t ems. Thes e functi ons are out li ned in t he rel evant s ect ionsof thi s manual .
The AJB is locat ed beneat h t he luggage compartment carpet , adjacent t he spare wheel wel l. The AJB i s a modular des ign,and compris es up t o 3 individual elements depending on vehicle specificati on. The AJB cont ains bl ade and J-cas e fuses ,and rel ays to di st ribute el ect ri cal power to sys t ems used at the rear of t he vehi cle. The AJB receives it s mai n power s upplyfrom the BJB.
Starter Fuse
ItemPart NumberDescription
1-Starter fus e
Incorporat ed i n the cable bet ween t he bat t ery and t he s tarter mot or/generat or is a CAL3 st art er fus e. The fus e is mount edadjacent t he batt ery pos it ive t erminal and is i ntegral wi th t he cable as s embly. In the event of fus e fai lure, t he completecabl e as sembl y mus t be repl aced.
Wire Color Codes
New wi re col or codes have been i ntroduced i n the El ect ri cal Ci rcuit Di agrams . Thes e new codes are s hown i n t he tablebelow.
ColorCode
BlackBK
BlueBUBrownBN
GreenGN
GreyGYOrangeOG
RedRD
Viol etVTW hi teW H
Y ell owY E
Tracer wire col or codes are s eparat ed from the main wi re col or code by a hyphen, t hus BU-RD equat es to a blue wire wit h ared tracer. For more informat ion, refer to t he Elect rical Circui t Diagrams and the El ect ri cal Library.
POWER MODES
The CJB cont rol s the power s uppl ies for the vari ous vehi cl e functi ons. There are 9 power modes availabl e which are usedby vari ous s ys tems to det ermi ne t he operati ng condit ion of t he vehi cle. Only 3 of thes e modes wil l be noti ceable t o t hedri ver and t echnici ans as foll ows:
Power mode 4 - Acces s oryPower mode 6 - Igni ti onPower mode 9 - Engine crank.
Transport Mode
All new vehicles will be del ivered from the factory in t rans port mode. Trans port mode repl aces t he t radit ional trans i t relayand inhibi ts a number of el ect ri cal s ys t ems and feat ures t o eli mi nat e quies cent drain from the bat tery during del ivery.W hen t he vehicle i s in transport mode 't rans p' wi ll be di spl ayed i n t he ins trument cl ust er odomet er.
To remove the vehicle from t rans port mode, the Land Rover approved di agnos ti c s ys t em mus t be connect ed during t hePre-Delivery Ins pect ion (PDI). For more i nformati on, refer t o the PDI manual .
Stop/Start Vehicles - From 2010 MY
Component Locat ion
The TD4_e is t he first Land Rover fit t ed wit h an i ntell igent ‘St op/Start’ s yst em; t he fol lowing component s have beenint roduced to support t he Stop/St art vehicle.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).

Opti mal batt ery healt h i s a fundamental fact or in t he correct operat ion of t he Stop/St art s ys tem, t herefore t o cal cul ate andcommunicate t he batt ery st atus a Batt ery Monit ori ng Syst em (BMS) module i s i nt roduced.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).
Voltage Quality Module
Duri ng an engine St op/Start cycle t he Volt age Quali ty Module (VQM) maintai ns the vehicle’s electrical s ys tems bys uppl yi ng a s upport volt age around the vehicle's electroni c components during an engine res tart. This al lows crucial vehicles ys t ems t o cont inue unint errupt ed when t here i s a s udden draw of current from t he batt ery.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).
BATTERY JUNCTION BOX

Relays
NameItem NumberVehicleDescriptionRelay R146Al lStarter mot or
Relay R249TD4BJB fus es 6, 8, 9, 11, 12 and 14
Relay R249i 6BJB fus es 1, 6, 8, 9, 11 and 12Relay R347Al lAir Condit ioning (A/C) compres s or cl utch
Relay R448TD4Glow plugs , BJB fus e 1
Relay R536Al lBJB fus es 39 (climat e control) and 45 (cigar light er/access ory socket)Relay R629Al lBJB fus es 34 and 35 (heated wi nds hiel d)
Relay R725Al lBJB fus es 37, 38, 41, 42, 43 and 44
Relay R835Al lW i ndshi el d wi per mot or (fast /sl ow s peed)Relay R932Al lHeadlamp was her pump
Relay R1028Al lLH horn, Ri ght Hand (RH) horn
Relay R1134Al lBJB rel ay 8 (winds hi eld wipers )Relay R1231Al lHeadlamp was her pump
Fuses
NameItemNumberVehicleDescription
FuseF11TD4Engine Cont rol Module (ECM) (gl owpl ug monit ori ng)
FuseF11i 6Diagnos t ic Monit ori ng of Tank Leakage (DMTL) leak det ect ion pump
FuseF22Automat ict rans mis s ionTransmis si on Control Module (TCM)
FuseF35AllEngine cooli ng fan modul e
FuseF46TD4BJB relay R4 (glow plugs)
FuseF57AllNot us ed
FuseF656TD4Front heat ed oxygen s ensor (HO2S)
FuseF656i 6HO2S', purge cont rol valve
FuseF757AllBJB relays R2 and R3
FuseF83TD4ECM (fuel injectors)
FuseF83i 6ECM (el ect ri c thrott le)
FuseF955TD4Mas s Ai r Flow (MAF) s ens or

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).