LAND ROVER FRELANDER 2 2006 Repair Manual

Speci al Tool (s ):
308-617 6.
7.
CAUTIONS: Make s ure that t he area around the component i s
clean and free of foreign materi al. Take extra care not t o damage t he mati ng faces .
Speci al Tool (s ): 308-615 ,
100-012 7.
Installation Speci al Tool (s ):
205-872 1.
To i nst all , revers e t he removal procedure.
2.
Check and top-up the t rans fer case fl uid l evel .
Refer t o: Transfer Case Fl uid Level Check (308-07B Transfer Case,
General Procedures).
3.

Publi s hed: 11-May-2011
Transfer Case - Transfer Case Vent
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.
2. CAUTION: Make s ure that the area around t hecomponent i s cl ean and free of foreign mat eri al .2.
Installation
To i nst all , revers e t he removal procedure.1.

Publi s hed: 11-May-2011
Exhaust System - I6 3.2L Petrol -
Lubricants, Fluids, Sealers and AdhesivesItemSpecification
Heated oxygen s ens or (H02S) removal*W D40 or Sui table al ternat ive
Heated oxygen s ens or (H02S) t hreadsApply s uit able hi gh temperat ure ant i-s ei ze compound t o t hreads of s ens or* Apply to area around sensor threads prior to attempting to remove sensor
General Specification
ItemSpecificationCatal yt ic convert ers- l ocat ionFi tt ed in the front s ect ion of t he exhaus t s yst em
Exhaus t manifoldsMani fold as s embli es (2) wi th three fabri cat ed branches mergi ng int o an int egral cat alyti c convert erare fit ted t o t he cyl inder head.
Exhaus t s yst ems t ainles s s teel exhaus t s ys t em s upplied as two separat e as sembl ies . Front s ect ion i ncorporat ing twocatal yt ic convert ers and a rear sect ion i ncorporat ing centre and rear s i lencers
Torque Specifications
DescriptionNmlb-ft
Catal ys t moni tor s ens or4533Catal yt ic convert er t o exhaus t mani fold bol ts *3022
Catal yt ic convert er t o centre muffl er nut s and ret aining cl amp2418
Exhaus t manifold bol tsAAExhaus t manifold heat shi el d bolt s107
Exhaus t s upport bracket s t o front subframe / floor bolt s2418
Exhaus t s upport bracket t o cent re bearing carrier bolt s2418Exhaus t t ai l pipe t ri m s crews32
Front muffl er s ervi ce sl eeve cl amp nuts4028
Heated oxygen s ens or (H02S)+4533* It is not appropriate to either fit or remove these fixings using air tools due to a risk of cold welding/snapping.
+ Apply anti-seize lubricant to threads of sensor - See Lubricants
A = refer to procedure for correct torque sequence

Publi s hed: 11-May-2011
Exhaust System - I6 3.2L Petrol - Exhaust System
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription1-Heated Oxygen Sens or (HO2S) - Pre-Cat al yst (2 off)
2-Gasket (2 off)
3-HO2S - Pos t cat alys t (2 off)4-Flexible coupli ng

5-Gasket
6-Tailpi pe fi nis her (opti onal )
7-Mount ing rubber (6 off)8-Rear muffler
9-Cent re muffler
10-Flange11-Bracket
12-Catalyt ic converter (2 off)
13-Flange14-Catalyt ic converter (2 off)
15-Exhaus t manifol d gas ket s
OVERVIEW
The 3.2L SI6 exhaus t s yst em i s fabricated from s tai nl ess st eel and is s upplied as two separat e as sembl ies ; a front s ect ionincorporat ing t wo catal yt ic convert ers and a rear sect ion i ncorporat ing centre and rear s i lencers.
EXHAUST MANIFOLDS
The exhaus t manifold compri s es two separat e manifold as s embli es . One mani fol d is us ed for cyli nders 1 t o 3 and thes econd mani fold is us ed for cyli nders 4 t o 6. The manifolds are s eal ed to the cyli nder head wi th a gas ket and s ecured wit h14 bolt s .
Each manifol d compri ses t hree fabri cat ed branches whi ch merge i nto an int egral cat alyti c convert er. A threaded bos s isposi ti oned where t he t hree branches merge and provi des for t he fi tment of a pre-catalys t HO2S. The cat alyti c convert eroutl et s have offs et flanges which mat e wi th corres pondi ng fl anges on t he front s ect ion exhaus t s ys tem.
A bracket on each out let flange all ows for t he att achment of an exhaus t mani fold heat s hield.
FRONT SECTION
The front sect ion has t wo flanged pi pes which mat e wi th the offs et fl anges of t he exhaus t manifol ds. The flanges ares eal ed wit h gas ket s and s ecured wit h bolt s . The fl anges are connected vi a curved pipes t o decouplers which provide afl exi ble joint i n the sys tem. The out let from each decoupl er compris es a curved pipe wit h a t hreaded bos s whi ch providesfor t he fit ment of a pos t -catal ys t HO2S.
Each pi pe is connect ed i nt o a smal ler catalyt ic converter whi ch in t urn is connected to a doubl e fl ange which mat es wit ht he rear s ect ion of t he exhaus t s ys t em.
Two mount ing rubbers are l ocat ed at the rear of the flexible coupli ng and are at t ached t o a bracket mounted on the fronts ubframe.
REAR SECTION
The rear s ect ion has a doubl e fl ange which mat es wit h t he doubl e fl ange of the front s ect ion. The doubl e flanges of eachs ect ion are s eal ed wi th a gas ket and s ecured wit h s tuds , washers and nuts . Two s hort pipes from the double fl angeconnect int o the cent re muffl er.
The cent re muffler is a fabricated unit wit h a capaci ty of 7.6 li ters. The muffl er compris es a pair of perforat ed baffle t ubescont ained wi thin the muffler body. The t wo baffle tubes merge into one s ingle t ube which provi des the out let from t hemuffler. A rubber mounti ng is at t ached t o t he rear of the muffler and att aches t o a hanger bracket l ocat ed on theunders ide of t he vehi cl e fl oorpan.
A s i ngl e pipe from t he rear of the centre muffl er is rout ed along t he unders ide of the vehi cl e body to the rear muffler. Thepipe ent ers t he rear muffl er t hrough a connect ion i n t he forward face of the muffl er.
The rear muffl er i s a fabri cat ed uni t wit h a capacit y of 29.3 l it ers . The rear muffler i s pos i ti oned t rans vers ely at t he rear oft he vehi cl e, forward of the rear bumper. The muffler compri ses baffl e plat es and perforated baffle tubes . Each end of t hemuffler body has an outl et which direct exhaus t gas ses to exit at t he rear of t he vehi cl e. The muffler is support ed by as ingle rubber mount ing on t he Left Hand (LH) s ide and by t wo rubber mounti ngs on the Right Hand (RH) s ide.
CATALYTIC CONVERTERS
The cat alyt ic converters are fit t ed in t he front s ect ion of t he exhaus t s ys t em, aft er the HO2S.
The HO2S moni tors the exhaust gas s es leavi ng t he engi ne. The engine management s ys t em us es t hi s informat ion t oprovide accuratel y met ered quant it ies of fuel t o t he combus t ion chambers t o ens ure the mos t efficient us e of fuel and t omi ni mi se the exhaus t emi s si ons .
In the cat alyti c convert ers , t he exhaus t gas es are pas s ed t hrough honeycombed ceramic el ement s coated wi th a s peci als urface t reat ment cal led 'was hcoat '. The was hcoat i ncreas es t he s urface area of the cerami c element s by a fact or ofapproximat el y 7000. O n top of t he was hcoat i s a coat ing cont ai ning plat inum, whi ch is t he act ive cons ti tuent forconvert ing harmful emi ss i ons into inert by-product s. The pl at inum adds oxygen t o the carbon monoxi de and thehydrocarbons i n t he exhaus t gases , to convert t hem i nto carbon di oxi de and water respecti vel y.

Publi s hed: 11-May-2011
Exhaust System - I6 3.2L Petrol - Exhaust System
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the exhaust s ys tem, refer t o t he relevant Descripti on and Operat ion s ect ion in t he works hopmanual. REFER to:
Exhaus t Sys t em (309-00A Exhaus t Sys t em - I6 3.2L Pet rol , Descri pti on and Operat ion),Exhaus t Sys t em (309-00B Exhaus t Sys t em - 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 s ys tem int egrit y and obvi ous s igns of mechanical damage.2.
Visual InspectionMechanical
LeaksMet al fati guePipes , mufflers and cat alyt ic convertersJointsMounti ngsClearance around component 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 ep.3.
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.4.
Symptom Chart
SymptomPossible CauseAction
Exces s ivelynois y/l eaki ng exhaus tExhaus tsys t em/component sInspect exhaus t sys t em, refer t o Vi sual Ins pect ion aboveRecti fy l eaks or Inst all new component s as neces s ary. Refert o Removal and Ins tall ati on ins truct ions i n t his s ect ion
Loss of powerRes t ri ct ed exhaus tsys t emFuel s yst emIgnit ion sys temElect roni c engi necont rol
Inst all new exhaus t component s as neces s ary. Refer t oRemoval and Ins tal lati on ins t ructi ons i n t his s ecti onFor fuel s ys t em t est s .REFER t o: Fuel Tank and Li nes (310-01A Fuel Tank and Li nes -I6 3.2L Pet rol , Diagnos is and Tes t ing).For ignit ion s ys tem tes t s.REFER t o: Engine Ignit ion (303-07A Engine Igni ti on, Diagnos isand Tes ti ng).For electroni c engi ne cont rol t est s .REFER t o: El ect ronic Engine Cont rol s (303-14A El ect ronicEngine Controls - I6 3.2L Petrol , Diagnosi s and Test ing) /Elect ronic Engine Cont rols - 2.2L Durat orq-TDCi (DW ) Di esel(303-14 Electronic Engine Controls - 3.2L, Di agnos is andTes ti ng).

Publi s hed: 11-May-2011
Exhaust System - I6 3.2L Petrol - Rear Muffler
Removal and Inst all ati on
Special T ool(s) 100-051
Cut ter, Exhaust Pi pe
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
1. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Rais e t he vehicle on a li ft .
1. Us ing t he s peci al t ool, cut the exhaust pi pe at a
dis t ance of 300mm from t he front of the rear muffler.
Speci al Tool (s ): 100-051 2.

3. W ARNING: Thi s s tep requi res t he aid of
another technician.
3.
Installation Inst all t he rear muffler and t ight en the s ervi ce sl eeve.
T orque: 40 Nm 1.

Publi s hed: 11-May-2011
Exhaust System - I6 3.2L Petrol - Front Muffler
Removal and Inst all ati on
Special T ool(s) 100-051
Cut ter, Exhaust Pi pe
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
1. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Rais e t he vehicle on a li ft .
1. Us ing t he s peci al t ool, cut the exhaust pi pe at a
dis t ance of 300mm from t he front of the rear muffler.
Speci al Tool (s ): 100-051 2.

3.
NOTE: Dis card t he gasket .
T orque: 25 Nm 3.
4.
Installation 1. NOTE: Ins t al l a new gas ket .
Inst all t he front muffler and ti ghten t he s ervice s leeve.
T orque: 40 Nm 1.