LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Electronic Engine Controls - TD4 2.2L Diesel - Oil Temperature Sensor
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
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 s tart er mot or.
Refer t o: Start er Motor (303-06B Starti ng Sys t em - TD4 2.2L Dies el,
Removal and Ins tall ati on).
2. 3. CAUTION: Make s ure that a new s eali ng was her
i s ins tal led.
T orque: 27 Nm 3.
Installation To i nst all , revers e t he removal procedure.
1.
Check and top-up the engine oi l if required.
2.

Publi s hed: 11-May-2011
Electronic Engine Controls - TD4 2.2L Diesel - Clutch Pedal Position (CPP)
SwitchLHD AWD
Removal and Inst all ati on
Removal
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).
1.
Remove t he dri ver l ower ai r bag.
Refer t o: Dri ver Lower Air Bag Module (501-20B SupplementalRes traint Sys t em, Removal and Inst all at ion).
2.
3.
Installation
To i nst all , revers e t he removal procedure.1.

Publi s hed: 11-May-2011
Electronic Engine Controls - TD4 2.2L Diesel - Clutch Pedal Position (CPP)
SwitchRHD AWD
Removal and Inst all ati on
Removal
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).
1.
Remove t he dri ver l ower ai r bag.
Refer t o: Dri ver Lower Air Bag Module (501-20B Supplemental
Res traint Sys t em, Removal and Inst all at ion).
2. 3.
4.
Installation To i nst all , revers e t he removal procedure.
1.

Publi s hed: 11-May-2011
Electronic Engine Controls - TD4 2.2L Diesel - Exhaust Gas Temperature
Sensor
Removal and Inst all ati on
Removal
W ARNING: Observe due care when worki ng near a hot exhaust s ys tem.
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
1. W ARNING: Do not work on or under a vehi cle s upported onl yby a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he engi ne cover.
Refer t o: Engi ne Cover - 2.2L Dies el (501-05, Removal andInst all at ion).
2.
3.

4. CAUTION: Before dis connecti ng or removing t he
component s, make sure t he area around t he joi nt faces
and connecti ons are clean. Plug open connecti ons to
prevent cont aminati on.
T orque: 35 Nm 4.
Installation Apply ant i-sei ze compound t o t he s ens or threads .
Refer t o: Specificati ons (303-08, Speci ficat ions).
1.
To i nst all , revers e t he removal procedure.
2.

Publi s hed: 11-May-2011
Electronic Engine Controls - TD4 2.2L Diesel - Diesel Particulate Filter (DPF)
Temperature Sensor
Removal and Inst all ati on
Removal W ARNING: Observe due care when worki ng near a hot exhaust s ys tem.
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
1. W ARNING: Do not work on or under a vehi cle s upported onl y
by a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
1. 2.
3. CAUTION: Before dis connecti ng or removing t he
component s, make sure t he area around t he joi nt faces
and connecti ons are clean. Plug open connecti ons to
prevent cont aminati on.
T orque: 35 Nm 3.
Installation Apply ant i-sei ze compound t o t he s ens or threads .
Refer t o: Specificati ons (303-08, Speci ficat ions).
1.
To i nst all , revers e t he removal procedure.
2.

Publi s hed: 11-May-2011
Automatic Transmission/Transaxle -
Lubricants, Fluids, Sealers and Adhesives
• CAUTIO NS:
* Do not us e any l ubricant other t han that s pecified
+ Do not over l ubricate
ItemSpecification
Recommended lubri cant - 3.2 Pet rol *Ess o JW S 3309 US. Land Rover Part No LR002748
Recommended lubri cant - 2.2 Dies el, Vehicles buil t up to 2011 *Ess o JW S 3309 US. Land Rover Part No LR002748Recommended lubri cant - 2.2 Dies el, Vehicles buil t from 2011 *Nippon AW -1. Land Rover Part No LR0022460
Torque converter nos e+Molykot e FB180
Driveshaft spl ine greas eW eicon Ant i Sei ze - 6G92M1C27AAFlui d pan to transmis si on s eal antLR002912
C apacities
CAUTION: * A fi nal oi l level /check/top-up mus t be carri ed out when the uni t has been i nst all ed
ItemCapacity (liters/pints/US quarts)Init ial dry fil l*7.0/12.3/7.4
General Specification
ItemSpecification
Automat ic trans mi ss i onAi s in AW F21 (6 s peed auto)T orque - Maximum:
3.2 Pet rol315 Nm (232 lb-ft )
2.2 Dies el450 Nm (332 lb-ft )Gear ratios:
Firs t4.148:1
Second2.370:1Third1.556:1
Fourt h1.155:1
Fifth0.859:1Sixt h0.686:1
Revers e3.394:1
Final drive ratio:3.2 Pet rol3.750:1
2.2 Dies el3.329:1
T orque converter:3.2 Pet rolD260 170K
2.2 Dies elD260 186K2
T ransmission control module:Locat ionIntegrat ed onto top trans mi ss i on cas ing
Type - 3.2 Pet rol , Vehi cl es bui lt from 2007 to 2009SH 7055
Type - 2.2 Dies el , Vehi cles buil t from 2007 t o 2010SH 7055Type - 3.2 Pet rol , Vehi lces bui lt up to 2011SH 7058
Type - 3.2 Pet rol and 2.2 Dies el, Vehicles buil t from 2011SH 7058
Torque Specifications
DescriptionNmlb-ft
3 way sol enoi d S11073 way sol enoi d S2107
Cover pl ate bol t - PTU s ide - 2.2 Dies el onl y2418
Cover pl ate bol t- s t arter s ide - 2.2 Di esel only2418Drai n plug bol t4735
Fil l pl ug Torx bol t3929
Flexplat e to torque convert er bol ts6044Flui d pan Torx bolt s1310
Lock pl ate bol t - oil t emperature s ens or107
Main cont rol valve body bol ts107Overflow Torx bolt75
Suct ion cover - val ve body as s y107
Trans mi ss ion cont rol module (TCM) bol ts2418Trans mi ss ion cont rol module (TCM) s upport bracket2518
Speed Sens or - Input53.7
T ransmission to engine bolts - M10:3.2 Pet rol4835
2.2 Dies el6548
Trans mi ss ion to engine bol ts - M8 - petrol 3.2l engi ne onl y2418

Publi s hed: 11-May-2011
Automatic Transmission/Transaxle - Transmission Description
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription1-Trans mi s si on s elect or lever ass embly
2-Cable bracket
3-Aut omati c transmis s ion4-Trans mi s si on Control Module (TCM)
5-Lever arm
6-Trans mi s si on fl uid cooler
OVERVIEW
The AW F21 aut omati c t rans mis s ion i s a 6 speed, elect roni cal ly control led uni t manufact ured by Ai s in AW i n Japan. Thet ransmis s ion represent s t he lat es t i n automat ic t rans mis s ion technol ogy for a t rans verse, Al l W heel Drive (AW D) unit . Thet ransmis s ion feat ures l ock-up s lip cont rol, 'CommandShi ft ™' functi ons and aut omati c and dri ver s electable modes to gi vet he opt imum on and off road performance.
The t ransmis s ion i s cont rol led by a TCM which contains s oftware to provide operat ion as a semi-aut omati c'CommandShift™ ' t rans mi ss ion. The TCM al lows t he t rans mis s ion t o be operat ed as a convent ional aut omati c unit bys elect ing P, R, N, D on t he s el ect or lever. Movement of t he s elector lever across the gat e t o t he 'M/S' pos it ion put s thet ransmis s ion i nt o el ect ronic 'Sport' mode. Furt her movement of the lever i n a l ongi tudinal direct ion t o t he + or – posi ti on

puts t he t rans mis s ion i nto el ect roni c manual 'CommandShift™ ' mode.For addit ional informat ion, refer t o: Ext ernal Control s (307-05 Automat ic Trans mi s si on/Trans axl e External Controls ,Des cript ion and Operat ion).
The AW F21 trans mi s si on has the foll owing feat ures :
Des igned to be maint enance freeTorque capacit y of 450 NmTrans mis s ion flui d is fi ll for l ifeThe t orque convert er features a control led s l ip feature wit h elect ronically regulat ed lock-up cont rol on gears 2 t o 6Shift programs controll ed by the TCMTCM has an adapti ve capabil it y to ens ure efficient gear s hift qualit y t hroughout t he s ervice l ife of the t rans mi ss i onDiagnost ics avail abl e from the TCM vi a t he high s peed Control ler Area Network (CAN) bus .
TRANSMISSION
The t ransmis s ion compri ses the mai n casi ng which hous es al l of the t rans mi ss ion components . The torque convert er islocated i n a separat e convert er hous i ng.
AW F21 Aut omat ic Trans mi ss ion - Sect ional Vi ew
ItemPart NumberDescription
1-Clut ch - C2
2-Brake - B23-One-way cl ut ch - F1
4-Clut ch - C1
5-Brake - B1

6-Clut ch - C3
7-Torque converter
8-Fluid pump9-Different ial as sembl y
10-Count er dri ven gear
11-Count er dri ve gearThe main cas ing ret ai ns the fl ui d at t he bot t om. A combined drai n/fill er plug i s located i n t he bot t om of t he cas ing. The oillevel is checked by removing t he inner fi ll plug when the t rans mis s ion flui d is at a t emperature of bet ween 50 t o 60°C (122t o 140°F). W hen the oi l fl ow becomes a dri p from the pl ug hol e, the l evel i s correct.
The t ransmis s ion has a flui d cool er whi ch is locat ed on t he Left Hand (LH) end of t he radi ator. The cooler is connect ed t ot he trans mi s si on convert er hous ing by 2 pipes . The fl ui d cooler is connect ed int o t he engi ne cool ing s yst em and cools thet ransmis s ion fluid by heat t rans fer t hrough t he cooler t o t he engi ne cool ant .For addit ional informat ion, refer t o: Trans mis s ion Cooli ng (307-02 Trans mis s ion/Trans axle Cooli ng, Des cri pti on andOperat ion).
TORQUE CONVERTER
ItemPart NumberDescription1-Torque convert er hous ing
2-Lock-up clut ch
3-Turbine4-Impell er
5-St ator
6-Fl uid pump7-Input shaft
The t orque convert er is t he coupl ing el ement bet ween the engine and the t rans mis s ion and is l ocat ed in t he t rans mis s ionhous i ng, on t he engine s ide of t he t rans mis s ion. The dri ven power from the engine cranks haft i s transmit ted hydrauli cal lyand mechani cal ly t hrough t he torque convert er t o t he t rans mis s ion. The torque convert er is connect ed to the engine by adri ve plate.
The t orque convert er compris es an i mpeller, a s tat or and a t urbine. The torque convert er is a sealed uni t wit h allcomponents locat ed between the converter housi ng cover and t he impel ler. The t wo component s are welded t oget her t oform a s eal ed, flui d fi ll ed hous ing. W it h the impell er welded t o the convert er hous ing cover, the impell er is t hereforedri ven at engine cranks haft s peed.
The t orque convert er cont ai ns a hydrauli cal ly operat ed lock-up clut ch which i s cont roll ed by t he TCM via a s olenoid i n t hevalve block which actuat es s pool valves to cont rol the hydraul ic pres s ure appli ed t o t he cl utch. Thi s all ows the TCM t oprovide 3 modes of convert er operat ion; unlocked, part iall y l ocked and ful ly l ocked.
VALVE BLOCK
The valve block is locat ed i n a vert ical pos i ti on at the front of t he transmis si on mai n cas i ng, behind a sealed cover. Thevalve block cont ains a number of s olenoids , dampers and s pool valves to cont rol t he trans mi s si on operati on. The s olenoidsare cont roll ed by t he TCM t o provide gear changes and s mooth trans i ti on bet ween rat io changes.