LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Engine Emission Control - TD4 2.2L Diesel -
Torque SpecificationsDescriptionNmlb-ft
Crankcas e vent oil s eparator97
Crankcas e vent oil s eparator, wiring harnes s bracket.107Crankcas e vent oil s eparator t o cylinder block, bracket.
M6107
M82518EGR Cooler bolt s107
EGR Cooler cros s -over pipe s ecuring bolt107
EGR Val ve inlet t ube bol ts107EGR Val ve out let t ube bol ts107
EGR Val ve nut s107
EGR Val ve screws64Exhaus t manifold heat shi el d107
Fuel fil ter brackets2518
HO2S W iring harnes s bracket86Intake manifold adaptor64
Intake manifold adaptor, wiring harnes s bracket107

Publ is hed: 10-Jun-2011
Engine Emission Control - TD4 2.2L Diesel - Engine Emission Control
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription
1-Cams haft cover2-Posi ti ve crankcas e vent il ati on (PCV) valve
3-Crankcas e gas vent to air int ake duct
4-Oil fil ler cap5-Oil return t ube
6-Crankcas e vent oil s eparator
7-Crankcas e gas venti lat ion t ube - s howi ng fl ow direct ion

ItemPart NumberDescription
1-Exhaus t gas t rans fer t ube - showi ng fl ow direct ion2-Throt t le body
3-Intake mani fold
4-Exhaus t mani fold5-Coolant i nl et
6-Exhaus t gas reci rculati on (EGR) cooler
7-Coolant outl et8-Exhaus t gas reci rculati on (EGR) Val ve and Act uator
OVERVIEW
Crankcase Ventilation System
To prevent the bui ld-up of gas es in the engine's crankcase, t he crankcas e gas es are drawn int o t he oil s eparator where oi lpart icles are removed from the gas es . The oi l is t hen drai ned down to the engine's oi l pan and the gas es are di rected intot he engi ne's air i nt ake s ys t em.
Pri or to t he oil -free gas es entering t he air i ntake s yst em, a pos it ive crankcas e venti lat ion (PCV) val ve operat es t omi ni mi ze crankcase pres sure vari at ions caused by engi ne air demand and engi ne operati ng condi ti ons .
Exhaust Gas R ecirculation (EGR) System
Harmful nit rogen oxides (NO x) a cons ti tuent of the exhaust gas es, are formed by t he react ion between oxygen andnit rogen at high t emperat ures . Reducing t he engine's combust ion temperat ure and t herefore t he amount of NO x producedis achieved by reci rculati ng a proporti on of the exhaust gas es. The reci rculat ed exhaus t gas es repl ace some of the engine'sint ake air as t hi s reduces the oxygen cont ent wit hin t he cyl inders and lowers t he peak combus t ion t emperat ure by s everalhundred degrees.
To reduce t he temperature as well as i ncreas e t he densi ty of t he i nducted fuel charge, t he recircul ated exhaus t gas es arepass ed t hrough t he Exhaus t Gas Reci rculati on (EGR) cooler. The EGR cool er ut il izes cool ant from t he engi ne cool ing s yst emt o reduce the exhaust gas t emperat ure. Exhaus t gas es ent ering t he EGR cooler reach temperatures of approxi matel y 500C;t he EGR cool er lowers t he t emperature of t he gas es , to 250-300C before t hey exit t he cool er.
SYSTEM OPERATION
CRANKCASE VENT ILAT ION SYST EM OPERAT IO N
Crankcas e gas s es are drawn int o t he oil s eparator unit from the crankcase and the oil pan by a vacuum creat ed by aconnecti on int o t he air inducti on sys t em.
The crankcas e gas ses are circul at ed around t he oil s eparator and t hrough t he cams haft cover where t he gas and oil ares eparated. The gas is returned to the i nlet s ide of t he air inducti on s ys t em prior to the t urbocharger. The collected oi l isdrai ned down to the s ump.
EXHAUST GAS RECIR CULAT ION (EGR) SYST EM
An elect ricall y actuated val ve, mounted on the out let s ide of t he EGR cooler and cont rol led by t he ECM (engi ne cont rol

module), regulates t he amount of exhaus t gas es reci rculated into the ai r int ake s ys tem. The ECM uses s i gnals fromvarious engine s ens ors and calculates a res pons e bas ed on t he embedded software algori thm t o cont rol exhaus t gasrecircul ati on. The ECM trans mi ts this cont rol s ignal t o t he valve's actuat or, which i s clos ed-loop controlled wit h t he mas sair flow (MAF) s ens or providi ng the feedback t o t he ECM.
COMPONENT DESCRIPTION
Exhaust Gas R ecirculation (EGR) Valve and Cooler Assembly
ItemPart NumberDescription1-Actuator
2-Coolant out let
3-CoolerThe EGR valve and cooler ass embl y is l ocat ed on t he RH s ide of t he cylinder head above t he exhaus t manifold, ands ecured wit h 4 fixi ngs . An i nl et pipe connects the EGR cooler t o t he exhaus t manifold. A gas t rans fer t ube is rout ed acros st he engi ne and connect s t he EGR valve out let t o the intake mani fold hous ing.
A pi pe on t he EGR cool er body connect s to the cl imat e cont rol heater outl et hos e, and provides t he cool ant s upply t o t heEGR cooler. The EGR cooler outl et connect s t o t he cool ant rail , locat ed on t he RH s ide of the engine. The cool ant rail isconnected bet ween the t hermal control modul e and the coolant pump rear hous ing.For addit ional informat ion, refer t o: Engi ne Cooling (303-03A Engine Cooli ng - I6 3.2L Pet rol, Des cri pt ion and Operati on).
The EGR i s cont rol led by t he ECM, and is enabled when t he engine meet s t he correct operati ng temperatures and undercruis i ng condit ions .
Oil Separator

The crankcas e venti lati on oil s eparator i s als o connected to t he oil fil ler t ube, located at t he rear LH si de of the engine. Oi lfor repl enis hing t he s ys t em pas ses through t he oil s eparator and return hos e, and int o t he oil pan. An oil baffle pl ate i sins t al led i n t he oil pan housi ng to reduce oil aerat ion and s plas h.

Publi s hed: 11-May-2011
Engine Emission Control - TD4 2.2L Diesel - Engine Emission Control
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the engine emis s ion control s ys tems , refer to the relevant Des cri pt ion and Operati on s ect ionin the workshop manual.REFER to: Engine Emi s si on Cont rol (303-08B Engine Emi ss i on Cont rol - TD4 2.2L Dies el, Des cript ion and Operat ion).
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.
Visual InspectionMechanicalElectrical
EGR valveEGR pi pes /hos esVacuum s ys t emEngine breat her s ys tem
W i ring harnes sElect rical connect or(s)Fus es (s )
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 , verify t he sympt om and refer t o t he Sympt om Chart, al ternat ively, check forDi agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
Symptom Chart
SymptomPossible CauseActionRough idl e, l ack of power under accel erati on,exces s ive fuel consumpt ion, exces s ive blacks moke
EGR valve s t uckCheck EGR valve for correct operati on.Check for relat ed DTCs and refer t o t he DTCIndex
Exces s ive engine bl ow-by/crankcas e press ureEngine breat her s ys temblocked/res trict edExces s ive engine wear
Check engine breat her s ys tem forbl ockage/res t ri ct ion. Check for exces si veengine wearREFER t o: Engi ne (303-00 Engi ne Sys t em -General Informati on, Di agnos is andTes t ing).
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 addi ti onalinformat ion read by the manufact urer approved diagnos t ic s ys tem).
• NOTE: W hen performing volt age or res is t ance t est s , always use a digi tal mult imeter (DMM) accurat e t o t hree deci malplaces, and wi th an up-t o-date cal ibrat ion cert ificate. W hen tes ti ng res is t ance al ways take t he res is t ance of t he DMMleads i nt 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: Ins pect connect ors for s igns of water ingres s , and pins for damage and/or corros ion.
• 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 .
DT CDescriptionPossible CauseAction
P040500Exhaus t Gas Recirculat ionSensor A Circuit LowEGR Valve pos it ion s ensorvol tage below lower li mitCarry out t he pinpoint t est s as sociat ed wit hthis DTC usi ng t he manufacturer approveddi agnos ti c s yst emP040600Exhaus t Gas Recirculat ionSensor A Circuit Hi ghEGR Valve pos it ion s ensorvol tage above upper l imi tCarry out t he pinpoint t est s as sociat ed wit hthis DTC usi ng t he manufacturer approveddi agnos ti c s yst em
P042E00Exhaus t Gas Recirculat ionControl St uck OpenEGR Valve s tuck duri ng normalengi ne running - at tempt t ouns t ick valve unsucces s ful
Check/clear EGR valve fromobs t ructi on/s ti cking

DT CDescriptionPossible CauseAction
P042F00Exhaus t Gas Recirculat ionControl St uck Clos edEGR Valve s tuck duri ng normalengi ne running - at tempt t ouns t ick valve unsucces s fulEGR Valve s tuck duri ng aft er runtes ts
Check/clear EGR valve fromobs t ructi on/s ti cking
P048900Exhaus t Gas Recirculat ionControl Ci rcuit LowEGR Valve pos it ion deviati on -val ve st uck openCheck/clear EGR valve fromobs t ructi on/s ti cking
P049000Exhaus t Gas Recirculat ionControl Ci rcuit Hi ghEGR Valve pos it ion deviati on -val ve st uck cl osedCheck/clear EGR valve fromobs t ructi on/s ti cking
P140200Exhaus t Gas Recirculat ionMet ering Ori ficeRes tricted
EGR val ve clos ed pos i ti on offsetdi fference wit h first learning toolargeEGR val ve clos ed pos i ti on offsetdi fference wit h previ ous learningtoo l arge
Check/clear EGR valve fromobs t ructi on/s ti cking, clear DTC and re-t es t . IfDTC remai ns , i ns t all new EGR valve
P148700Exhaus t Gas Recirculat ionCheck Sol enoi d Circui tEGR val ve H-Bridge driver errorCl ear the DTC and re-t es t. If the DTCremains , ins t al l a new ECM
P154500Exhaus t Gas Recirculat ionHi gh Side Control Ci rcuit /Open
Exhaust gas reci rculat ion controlci rcuit 1 (pos it ive) - open ci rcuitExhaust gas reci rculat ion controlci rcuit 2 (negat ive) - open circui t
Refer to el ect ri cal circui t diagrams and checkexhaust gas reci rculat ion control circui t foropen circui t
P154611Exhaus t Gas Recirculat ionHi gh Side Control Ci rcuitLow
Exhaust gas reci rculat ion controlci rcuit 1 (pos it ive) - short togroundExhaust gas reci rculat ion controlci rcuit 2 (negat ive) - s hort t oground
Refer to el ect ri cal circui t diagrams and checkexhaust gas reci rculat ion control circui t forshort to ground
P154712Exhaus t Gas Recirculat ionHi gh Side Control Ci rcuitHi gh
Exhaust gas reci rculat ion controlci rcuit 1 (pos it ive) - short topowerExhaust gas reci rculat ion controlci rcuit 2 (negat ive) - s hort t opower
Refer to el ect ri cal circui t diagrams and checkexhaust gas reci rculat ion control circui t forshort to power

Publi s hed: 11-May-2011
Engine Emission Control - TD4 2.2L Diesel - Exhaust Gas Recirculation
(EGR) Valve
Removal and Inst all ati on
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.
Remove t he EGR cool er.
Refer t o: Exhaus t Gas Reci rculati on (EGR) Cooler (303-08B Engi neEmi ss i on Cont rol - TD4 2.2L Dies el, Removal and Ins tall ati on).
2.
Installation
Inst all t he EGR cool er.
Refer t o: Exhaus t Gas Reci rculati on (EGR) Cooler (303-08B Engi neEmi ss i on Cont rol - TD4 2.2L Dies el, Removal and Ins tall ati on).
1.

Publi s hed: 11-May-2011
Engine Emission Control - TD4 2.2L Diesel - Exhaust Gas Recirculation
(EGR) Cooler
Removal and Inst all ati on
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.
Remove t he s econdary bulkhead cent er panel.
Refer t o: Secondary Bulkhead Cent er Panel - TD4 2.2L Dies el(501-02 Front End Body Panel s, Removal and Ins tal lati on).
2.
Drai n t he cool ant .
Refer t o: Cool ing Sys tem Drai ni ng, Fi lli ng and Bleeding (303-03BEngine Cooli ng - TD4 2.2L Di esel , General Procedures ).
3.
Remove t he heat ed oxygen s ens or (HO2S).
Refer t o: Heat ed Oxygen Sens or (HO2S) (303-14B Electroni c EngineControls - TD4 2.2L Dies el, Removal and Ins tal lati on).
4.
5.
6.

7.
8. CAUTIONS:
Make s ure that all openings are sealed. Us e newblanking caps.
Di s card the component.
8.