LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Exhaust System - I6 3.2L Petrol - Catalytic Converter
Removal and Inst all ati on
Special T ool(s) 310-121
W rench, H02S
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.
Remove t he front spl as h s hiel d.
Refer t o: Engi ne Unders hi eld (501-02 Front End Body Panel s ,
Removal and Ins tall ati on).
2. 3.
T orque:
25 Nm 4.

5. CAUTION: Di scard the bolt s .
T orque: 27 Nm 5.
Speci al Tool (s ):
310-121 T orque:
M18 45 Nm M5
6 Nm 6.
Installation To i nst all , revers e t he removal procedure.
1.
2. NOTE: For NAS vehicl es onl y.
If required, carry out a l ong drive cycl e.
Refer t o: Powertrain Cont rol Modul e (PCM) Long Drive Cycle Sel f-Tes t
(303-14 Electroni c Engine Controls - 3.2L, General Procedures).
2.

Publi s hed: 11-May-2011
Exhaust System - I6 3.2L Petrol - Exhaust System
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.
All vehicles
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.
Vehicles with petrol engine T orque:
25 Nm 2.
Vehicles with diesel engine T orque:
40 Nm 3.
All vehicles

4. W ARNING: Thi s s tep requi res t he aid ofanother technician.4.
Vehicles with petrol engine
Remove and dis card t he gas ket .5.
All vehicles
6. NOTE: Do not dis ass embl e further if t he component i s removedfor acces s onl y.
Remove t he rubber mount s .
6.
Installation
To i nst all , revers e t he removal procedure.1.

Publi s hed: 11-May-2011
Exhaust System - TD4 2.2L Diesel -
Lubricants, Fluids, Sealers and AdhesivesItemSpecification
Heated oxygen s ens or (H02S) removal*W D40 or s uit able 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 -t ype/locat ionAn oxidizi ng cat alyti c convert er is fit t ed in t he front s ect ion of t he exhaus t s ys t em
Exhaus t manifold -Locat ionA mani fold ass embly is fit ted to t he cylinder head.
Exhaus t s yst emStai nl ess st eel exhaust s ys tem s uppl ied as t wo s eparate ass embli es. Front s ecti on incorporat inga catal yt ic converter and a rear s ect ion i ncorporat ing a rear s il encer
Torque Specifications
DescriptionNmlb-ft
Catal yt ic convert er t o center s ect ion retai ning clamp4030Catal yt ic convert er t o t urbocharger hous ing retaini ng clamp107
Exhaus t manifold el bow t o EGR cool er2518
Exhaus t manifold heat s hield bol ts107Exhaus t manifold heat s hield nut s107
Exhaus t manifold retai ni ng nuts2418
Exhaus t manifold retai ni ng s tuds75Exhaus t s upport bracket s t o s ubframe / fl oor2518
Heated oxygen s ens or (H02S)++4533
+ Apply anti-seize lubricant to threads of sensor - See Lubricants

Publi s hed: 11-May-2011
Exhaust System - TD4 2.2L Diesel - Exhaust System
Des cript ion and Operat ion
COMPONENT LOCATION - WITH DIESEL PARTICULATE FILTER
ItemPart NumberDescription1-Exhaus t mani fold (ref onl y)
2-Pres s ure di fferenti al sens or
3-Heat ed Oxygen Sens or (HO2S) (ref onl y)4-Cat al yti c convert er

5-Gas ket
6-'Torca' clamp
7-Connect ing pi pe8-Mounti ng rubber (6 off)
9-Rear muffler
10-Di esel Part iculat e Filt er (DPF)11-Flange
12-Body hanger
13-Decoupl er14-Out let elbow
15-'V' clamp and gasket
16-Turbocharger (ref onl y)
COMPONENT LOCATION - WITHOUT DIESEL PARTICULATE FILTER

ItemPart NumberDescription
1-Exhaust mani fol d (ref only)2-HO2S (ref onl y)
3-Cat alyt ic converter
4-'Torca' joint5-Rear connecti ng pipe
6-Mount ing rubber (5 off)
7-Rear muffl er8-Front connect ing pi pe
9-Body hanger
10-Decoupler11-Outl et el bow

12-'V' cl amp and gas ket
13-Turbocharger (ref only)
OVERVIEW
The 2.2L DW 12 exhaus t s ys t em i s fabricated from s tainl ess st eel and i s s uppl ied as two s eparat e as sembl ies ; a fronts ect ion i ncorporati ng a catalyt ic converter and a rear sect ion i ncorporat ing a rear s il encer.
In s ome market s , the exhaus t s yst em incorporates a Dies el Parti cul ate Fi lt er (DPF) which all ows the vehicl e to exceedEuropean Stage 4 emis s ion s tandards .
The s ys t em i s att ached to t he unders ide of t he body wit h s ix mount ing rubbers (fi ve mount ing rubbers on vehicles wi thoutDPF) which are locat ed on mild st eel hanger bars t hat are wel ded to t he s yst em. The mounti ng rubbers locat e oncorres pondi ng hangers which are welded or bolt ed to the unders i de of the vehicle body.
FRONT SECTION
The front sect ion has a flared end which mat es wit h a corres ponding feature on t he turbocharger. The joint i s s ecuredt oget her us ing a 'V' band cl amp s ealed wi th a gasket .
The fl ange is formed on a fabricated out let elbow whi ch in turn is wel ded to the de-coupler. The elbow i ncorporat es at hreaded bos s whi ch provi des the locat ion for the HO2S. The decoupl er, which provi des a fl exi ble joint, i s welded t o t hebody of the catal yt ic convert er.
Vehicles without DPF
A s hort front connecti ng pipe s ecti on from t he catalyt ic converter mat es wit h t he rear connect ing pipe of t he s yst em and iss ecured wit h a 'Torca' joint. A mounti ng rubber is l ocat ed near t o t he cat alys t and att aches t o a body hanger bracketmounted on the body.
Vehicles with DPF
The cat alyt ic converter has a flange and gasket joi nt which mat es wit h a fl ange on the DPF. The DPF outl et has a s hortfront connect ing pi pe which mat es wi th t he rear connect ing pipe of t he s yst em and is s ecured wi th flange joint. Twomounti ng rubbers are l ocated near t o t he cat alys t and att ach to a body hanger bracket mount ed on the body.
REAR SECTION
The rear s ect ion has l ong connecti ng pipe s ect ion whi ch mat es wit h t he front connecting pi pe behi nd the cat alyst or DPFand is secured wi th a 'Torca' joi nt. The pipe secti on is routed al ong the unders i de of the vehicle and connect s int o t heRight Hand (RH) end of t he rear 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 muffler cont ains perforat ed baffl es and t ubes whi chreduce nois e as t he exhaus t gases pas s t hrough the si lencer. The exhaus t gas s es enter t he muffler at t he Right Hand (RH)end and exit via a pipe on t he Left Hand (LH) end. The exit pi pe faces the rear of the vehicle and is curved downwards t odirect exhaus t gas ses away from t he rear of the vehicle.
CATALYTIC CONVERTER
The oxidizing cat al yti c convert er, which has a capacit y of 2 li ters, i s fit ted i n t he front secti on of the exhaust sys tem, aftert he HO2S. The cat al yti c convert er is common t o vehicles wi th or wit hout t he DPF.
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 ze the exhaus t emi s si ons .
To furt her reduce t he carbon monoxi de and hydrocarbons content of t he exhaus t gas es , a catalyt ic converter i s int egratedint o t he front pi pe of the exhaust sys tem. In t he catalyt ic converter t he exhaus t gases are pass ed t hrough honeycombedceramic el ements coated wit h a s peci al surface t reatment call ed 'was hcoat '.
The was hcoat increas es the surface area of t he cerami c elements by a fact or of approximat ely 7000. On t op of thewas hcoat is a coat ing contai ni ng plat inum, which i s t he act ive const it uent for convert ing harmful emi ss i ons i nto inertby-products . The plat inum adds oxygen to t he carbon monoxide and t he hydrocarbons in t he exhaus t gases , t o convertt hem int o carbon dioxide and wat er res pect ively.
DIESEL PARTICULATE FILTER (if fitted)
The Dies el Parti cul ate Fi lt er (DPF) s ys t em reduces dies el parti cul at e emi s si ons to negl igible levels .
DPF Syst em Components

ItemPart NumberDescription
1-Temperat ure s ensor2-HO2S
3-Different ial pres s ure sens or
4-High pres sure s ens or pipe5-Low pres s ure sens or pi pe
6-Dies el part icul ate fi lt er
7-Temperat ure s ensorThe part iculate emis s ions are the bl ack fumes emi tt ed from the di es el engi ne under cert ain load condi ti ons . The emis s ionsare a complex mi xt ure of sol id and l iquid component s wi th the majori ty of t he part iculat es bei ng carbon mi crospheres onwhich hydrocarbons from t he engine's fuel and l ubricant condense.
The DPF s yst em compris es the foll owing component s:
Dies el parti cul ate fil terDPF cont rol s oft ware incorporated into the Engine Cont rol Module (ECM)Different ial pres s ure s ens or.
Diesel Particulate Filter
The DPF is locat ed i n t he exhaus t sys tem, downs tream of t he cat alyt ic converter. A major feature of the DPF i s i ts abil it yfor regenerat ion. Regenerat ion is t he burning of parti culat es t rapped by the fil ter t o prevent obst ructi on t o t he free fl ow ofexhaus t gass es . The regenerati on proces s t akes place at cal cul at ed i nt ervals and is not noti ceable by the driver of thevehi cl e.
Regenerat ion is mos t i mport ant , s ince an overfi ll ed fi lt er can damage t he engine t hrough exces si ve exhaus t back press ureand can it s el f be damaged or des t royed. The mat eri al t rapped i n t he fi lt er i s i n the most part carbon part icles wi th some