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andrew.aa



Member Since: 16 Aug 2011
Location: PERUGIA
Posts: 102

Italy 2004 Range Rover Westminster 4.4 V8 Java Black
BOSCH Water Cooled Alternator 150A REPAIR

As someone already knows, I have the problem of bad alternator, BOSCH WATER COOLED ALTERNATOR, that sometimes charge and sometimes not.
I hope this, give the right help to someone, 02/05 4.4 FFRR Owner..

Looking on the web discovered that this alternator has been used by BMW / Rolls Royce / LAND ROVER (IG-L terminal) and Mercedes (L-DFM terminal), and than there are two types: 150 AMP and 180 AMP output- We have 150 Amp version fitted on FFRR
The Alternator part number is:
BMW: 12311705483 to 12317508052 - 12317508054-1705483
LAND ROVER: YLE000040
for Références:
BOSCH: 01220AA1J0 - 01220AA1J0WH - 01220AA1S0 - 01220AA1S0WH 0122468015 - 0122468015WH - 0986041750

There are also many other aftermarket brand codes for this alternator.

The most likely known causes of bad alternator can be in order of percentage,

1 voltage regulator
2 diodes
3 tollerance ring and / or Bearings

This kind of alternator it has the ability to switch the output off completely, and when to when starting the car, at full throttle, with the DME control
Bosch unfortunately does not provide spare parts, but all can be found aftermarket.
But you can also buy an alternator overhauled and guaranteed, ar some repair kit available online.

I prefer to repair the old one, knowing to put quality parts, so I removed my alternator, and I noticed that the manufacture date was April / year 2008.
not too much old, but I'm surev damaged the voltage regulator with an inadvertent battery short circuit.
There are many tutorials online, how to replace Bosch water cooled alternator, that is not much difficult, and so I will limit only to discuss about components inside this rare alternator.

So, fiirst of all remove flange nut pulley 14mm socket, keeping the pulley with a snap clamp, and once removed the nut pulley easily come out


then remove the four cover screws Torx T25 (green circle), being careful because they are very narrow, and the nut in the B + (red circle)


Before removing the cover, make attention to remove the sealant around.
Now it is possible to remove the voltage regulator by removing the three Torx silver (blue circle)
to disassemble the rectifier you have to remover the other silver Torx and the brass, near the pad (orange circle). and the two external torx, on the sides


the rectifier bridge with six diodes welded and rotor will go out all together


I also found broken tollerance ring and pulley damaged.



the alternator is composed as shown in figure




the only parts provided by LAND ROVER and BMW are the outer gasket and the pulley, and of course a complete alternator
below all codes bosch and reference for each part are:



Click image to enlarge






diodes can be found online for a few euro, must be three positive and three negative 50 amps or higher, if you do not want to buy the full rectifier.



There are also repair kit online, including what you want, but I don't know the quality.
Infact I bought regulator type monark 082 989 200, thinking it was good German quality, however very disappointed.


Bearings and more, bought by woodauto UK, really friendly and efficient.

OEM bearings are KOYO / Ball Bearing 6203 2RS ​​-17x40x12 mm and Ball Bearing 6304 EHSR 2RS - 17x52x17 mm (mean 2rs double rubber sealed), but you can take any quality you want like SKF / FAG / NSK ETC ..

I will complete repair guide as receive all parts.
Hope everything is clear,even though my bad English.

Last edited by andrew.aa on 18th Oct 2015 2:15pm. Edited 1 time in total

Post #352710 17th Oct 2015 11:41am
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ironhorse



Member Since: 13 Dec 2013
Location: birmingham
Posts: 346

United Kingdom 2003 Range Rover Vogue 4.4 V8 Giverny Green

All good so far
Got one to repair so looking forward to rest of your overhaul Thumbs Up

Post #352729 17th Oct 2015 3:31pm
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Zirconblue



Member Since: 16 Apr 2015
Location: Kent
Posts: 1277

United Kingdom 2005 Range Rover Vogue 4.4 V8 Cairns Blue

So the pattern regulator appears to be made in Germany, whereas the Bosch one is "Made in GB".

Post #352754 17th Oct 2015 5:59pm
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Welshdragon



Member Since: 20 Jan 2012
Location: here and there...but not where I should be
Posts: 1831

Wales 2003 Range Rover Vogue 4.4 V8 Monte Carlo Blue

Now this could be very handy in the future......Stan.....you know what to do Wink

Look forward to the rest of the rebuild Thumbs Up If it dont work.......burn it!

If the IId tool cant fix it.......burn the FF.

If the FF cant be fixed......buy a Land Cruiser!

If the LC cant be fixed..............................................BUY a horse !!

Post #352776 17th Oct 2015 7:45pm
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EmiratesA380



Member Since: 14 Jan 2015
Location: england
Posts: 323

United Kingdom 

Censored andrew.aa

I thought I was up on this all too - top marks for this one

I am going to have a go too

Thumps up for posting - thanks Thumbs Up

Post #352783 17th Oct 2015 9:26pm
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andrew.aa



Member Since: 16 Aug 2011
Location: PERUGIA
Posts: 102

Italy 2004 Range Rover Westminster 4.4 V8 Java Black

Zirconblue wrote:
So the pattern regulator appears to be made in Germany, whereas the Bosch one is "Made in GB".

always make attention, because OEM BOSCH is marked ''MADE IN GB'' meanwhile the other one is only marked ''GERMANY'' that does not mean, made in Germany, but onlly from Germany or something like that.
Unfortunately there is no way, to have the original part, at least I was not able to find it.
For what I can understand, most of these voltage regulator as spare, are made in CHINA /TAIWAN, and rebranded.
You can see that is a bit different from original, with small circuit, invisible on the original part.

Post #352881 18th Oct 2015 12:54pm
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Zirconblue



Member Since: 16 Apr 2015
Location: Kent
Posts: 1277

United Kingdom 2005 Range Rover Vogue 4.4 V8 Cairns Blue

Quote:
marked ''GERMANY'' that does not mean, made in Germany


That may be true, but not everything made in Germany is good quality, in the same way not everything made in China is rubbish. Smile

Post #352970 18th Oct 2015 9:32pm
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Haylands



Member Since: 04 Mar 2014
Location: North Ferriby, East Yorkshire
Posts: 4749

England 2002 Range Rover Vogue 4.4 V8 Epsom Green

Emirates777 wrote:
Censored andrew.aa

I thought I was up on this all too - top marks for this one

I am going to have a go too

Thumps up for posting - thanks Thumbs Up


This alternator was only fitted to the early 4.4 V8 M62 BMW engine, yours is totally different... Thumbs Up Pete
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Post #352973 18th Oct 2015 9:55pm
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kanikune



Member Since: 29 Oct 2017
Location: Teerijarvi
Posts: 13

Finland 2004 Range Rover Vogue 4.4 V8 Epsom Green

Did you got this sorted?

Post #501732 15th Jan 2019 8:41pm
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Gsxr1250dave



Member Since: 20 Oct 2018
Location: London
Posts: 204

England 

This is 4 years old don't expect a reply

Post #501763 16th Jan 2019 1:34am
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