LAND ROVER FRELANDER 2 2006 Repair Manual

ItemPart NumberDescription1-O ut er t appet2-Locking pin, outer3-Inner t appet4-Locking pin wit h s pring, inner5-O il inlet , hydraulic valve adjus tment6-Hydraulic valve adjus tment unit7-Return s pring, out er t appet8-Lug9-O il inlet , CPS functionThe elect rical hydraulic valves are seat valves .
The valves have 3 input s /outputs :
Inlet , oil s upplyTo/from tappetTo return, i.e. oil pan
A s olenoid is affected via an elect ro-magnet, which affect s a valve t hat can as sume 2 pos itions .
W hen the s olenoid is not activat ed, t he valve is only affect ed by the oil pres s ure on the intake s ide. The valve clos es for int akebut opens bet ween t he t appet and return.
The oil pres sure is low at t he t appet 's out er locking pin and t he valves lift a s mall amount .
W hen the s olenoid is act ivated, t he valve is affected from above by an elect ro-magnet that overpowers t he force of t he oilpress ure.
The valve s hift s posit ion and clos es bet ween t he tappet and ret urn but opens the connect ions between int ake and t appet .
The oil pres sure is high at t he tappet 's out er locking pin t hat is lifted and affects t he inner locking pin. Outer and inner t appetconnect and the valves lift a great er amount.

The intake camshaft is equipped wit h 3 lobes for each valve. One cent rally locat ed wit h a small lift ing height of 3.6 mm, and 2out er lobes wit h great er (s ame) lifting height s of 10.0 mm.
At small lift ing height s, only t he cent rally locat ed lobe works on t he valve, which occurs via t he inner t appet . The out er lobes workon the outer t appet t hat follows t he movement of t he lobes. The ret urn spring is compres s ed and ens ures that t he tappet isalways in cont act wit h t he camshaft . W hen the cent rally locat ed t appet and t he out er t appet are not joined, t he outer tappetmoves without affect ing the valve. Thus the lifting height is s mall. At high lift ing height, t he inner t appet and t he out er t appet arejoined via t he 2 lock pins .
The pos it ion of the lock pins is cont rolled hydraulically by 2 elect ro-hydraulic CPS solenoid valves . Thes e valves are locat ed in t hecams haft hous ing.
ItemPart NumberDescription1-CPS s olenoid valve - cylinders 3, 5 and 62-CPS s olenoid valve - cylinders 1, 2 and 4

One s olenoid cont rols t he valves for cylinders 1, 2 and 4 whils t t he other cont rols t he valves for cylinders 3, 5 and 6. The solenoidstherefore cont rol 6 valves each (when t he engine has 2 int ake valves and 2 exhaus t valves per cylinder).
The pos it ion of the s olenoids valves , on or off, are cont rolled by t he ECMFor addit ional information, refer t o: Elect ronic Engine Cont rols (303-14A Elect ronic Engine Controls - I6 3.2L Pet rol, Des cript ion andOperation)..
The inner t appet works like a hydraulic t appet , which compens at es for any wear. The valve clearance is t herefore '0'.
The exhaus t cams haft is convent ional and has a lift ing height of 10.0 mm. The t appets are mechanical (i.e. have valve clearance).
Cams haft Dat a
Intake
O pening angle, 3.6, mm lifting height:- Cranks haft degrees - 152°- Cranks haft degrees - 76°O pening angle, 10.0 mm lifting height :- Cranks haft degrees - 240°- Cranks haft degrees - 120°
Exhaus t
O pening angle, 10.0 mm lifting height :- Cranks haft degrees - 240°- Cranks haft degrees - 120°
The intake camshaft has a VCT unit .
Lifting heightOpensClosesIntake 3.6 mm32 BTDC t o 28 ATDC120 ATDC t o 180 ATDC (or 60 BBDC to 0 BBDC)Intake 10.0 mm37 BTDC t o 23 ATDC203 ATDC t o 263 ATDC (or 23 ABDC to 83 ABDC)Exhaust, 10.0 mm228 BTDC (or 48 BBDC)12 ATDC
BTDC = Before Top Dead Cent reABDC = Aft er Bot tom Dead Cent reBBDC = Before Bot t om Dead CentreATDC = Aft er Top Dead Cent re
Cams haft Posit ion in Relat ion t o Load and RPM
ItemPart NumberDescription1-Range for lifting height 3.6 mm2-Range for lifting height 10.0 mm3-Small lift ing height, 'early' camshaft4-Small lift ing height, 'lat e' cams haft5-Large lift ing height, 'early' camshaft6-Large lift ing height, 'lat e' cams haftBy closing t he int ake valves early at low load and low engine s peed, reduced fuel cons umption is achieved.

ItemPart NumberDescription1-CPS s olenoid valve (x 2)2-Oil circuit , t appet CPS funct ion3-Calibrated pass age (choke)4-To bearing, exhaus t cams haft5-Tensioner, cams haft chain6-Noz zle, cams haft chain lubricat ion7-Oil circuit , hydraulic adjus ting valve clearance8-Vacuum pump9-VCT unit10-Oil inlet , rear11-Ret urn12-To bearing, int ake cams haft13-To front bearing, intake camshaft14-Ret urn15-Oil inlet , front16-BleedingThe oil inlet , locat ed on the front edge of t he cylinder, s upplies oil t o t he following:
The hydraulic t appet sThe vacuum pumpThe noz zle for cam chain lubricat ionThe int ake cams haft 's front bearingThe electro-hydraulic CPS s olenoid valves , front and rearThe t appet s with CPS funct ion
There is a bleed valve (16) in t he duct for t he rear elect ro-hydraulic s olenoid valves .
The duct is als o equipped wit h 2 calibrat ed pas sages (3) t o each tappet circuit (2) (i.e. the circuits aft er t he CPS s olenoid valves ).A cont inuous flow through t he circuit ens ures t he neces s ary s t able pres sure differences that are neces s ary for a st able trans ferbet ween the s mall and large t appet (or vice vers a).
• NOTE: In t he event of a s mall lifting height , the t appet circuit , in principle, has no pres s ure when the CPS valves are open, whichproduces a ret urn flow t o t he oil pan.
A filt er is locat ed in each pass age.
The oil inlet , locat ed on the rear edge of t he cylinder, s upplies oil t o the following:
The camshaft chain's hydraulic t ens ionerThe int ake cams haft VCT unitThe int ake cams haft 's bearingsThe exhaus t cams haft's bearings
To switch from low lift t o high lift and vice vers a as s moot hly as pos sible, t he trans fer is only permitt ed when cert ain condit ionsare complet ed. Thes e are:
That the oil t emperature is above +40°C (104°F). Calculat ed int ernally in the ECM, from, amongst ot her t hings , t he coolantt emperatureO ccasionally t he volumetric efficiency is t he s ame for low and high lift , which means t hat the air requirement is wit hin arange where it can be managed init ially by VCT cont rol. This is t o achieve as soft a trans fer as pos sible.It is pos sible t o adjust ignition t iming t o prevent t orque peaks during CPS cont rol

For addit ional information, refer t o: Elect ronic Engine Cont rols (303-14A Elect ronic Engine Controls - I6 3.2L Pet rol, Des cript ion andOperation).
Variable Camshaft Timing Solenoid and Camshaft Position Sensors
ItemPart NumberDescription1-CMP Sens or - exhaus t cams haft2-VCT s olenoid3-CMP Sens or - intake camshaftThe profile, or pos ition and shape of the cams haft lobes are opt imiz ed for a cert ain engine rpm, but this normally limit s low-endtorque or high-end power. At high engine s peeds , an engine requires large amounts of air. However, t he intake valves may clos ebefore all t he air has been given a chance t o flow in. On t he other hand, if the cams haft keeps t he valves open for longer periodsof time, problems st art t o occur at t he lower engine speeds . This will caus e unburnt fuel t o exit t he engine s ince t he valves arest ill open.
To overcome t his , VCT changes t he valve t iming by eit her advancing or ret arding the cams haft s t o allow for opt imum engineperformance, reduced emis s ions, and increased fuel efficiency. This is achieved via an electronically controlled hydraulic s olenoidvalve locat ed in t he camshaft housing at t he rear of t he engine, behind the rear CPS s olenoid. The ECM t rans mit s a signal t o thesolenoid, which direct s engine oil int o t he VCT unit. A valve s pool in the VCT unit regulat es t he flow of oil.For addit ional information, refer t o: Elect ronic Engine Cont rols (303-14A Elect ronic Engine Controls - I6 3.2L Pet rol, Des cript ion andOperation)..
There are 2 CMP s ens ors locat ed in t he camshaft housing. The CMP s ensors monitor the posit ion of the cams haft s t o est ablis hignit ion t iming order, fuel injection t riggering and for accurate VCT cams haft advance-retard t iming feedback.
The CMP sensor is a Hall-effect s ens or, which s wit ches a batt ery fed supply on and off. The s upply is s wit ched when t he t eet h ofthe reluct or pas s by t he tip of t he sens or. The 4 t eet h are of differing s hapes , s o the ECM can determine t he exact pos it ion of t hecams haft at any t ime.For addit ional information, refer t o: Elect ronic Engine Cont rols (303-14A Elect ronic Engine Controls - I6 3.2L Pet rol, Des cript ion andOperation).
Spark Plugs

ItemPart NumberDescription1-Spark plug (6 of)The s park plugs s crew into t he cylinder head t hrough the cams haft hous ing and are controlled by the ECM via individual coils .
Ignition Coils

ItemPart NumberDescription1-Ignition coil (6 off)The ECM us es a s eparat e ignit ion coil for each spark plug. The ignit ion coils are of t he plug t op des ign, which at t ach t o t he t op ofthe s park plug. The coils are s ecured to the cams haft hous ing wit h a bolt.
The coil has a rubber seal, which s eals t he coil in the s park plug hole in t he cylinder head, prevent ing t he ingres s of mois t ure anddebris around t he spark plug. Thes e coils eliminat e t he requirement for HT leads , which in turn improves t he ignition s ys t emreliabilit y.
Each coil has a 3-pin female connect or, which provide for a bat tery volt age ignit ion feed, an eart h for t he s econdary winding and aprimary winding negat ive (s wit ch) terminal. The s wit ch t erminal of each coil is connect ed t o a separat e pin on t he ECM to allowindependent s wit ching.For addit ional information, refer t o: Elect ronic Engine Cont rols (303-14A Elect ronic Engine Controls - I6 3.2L Pet rol, Des cript ion andOperation).
Fuel Rail and Injectors

ItemPart NumberDescription1-Fuel rail2-Fuel rail pres s ure and t emperat ure sensor3-Fuel pres s ure pipeThe fuel rail maint ains a fuel pres sure of 3.8 bar (55 ps i) above manifold depres s ion under normal operat ing condit ions , t houghthis is programmed t o ris e t o 4.2 bar (61 ps i) in res pons e t o either:
Cold st art condit ions , t o improve fuel vaporiz ationCold fuel conditions , as the colder t he fuel t he higher vis cos it y
The fuel rail is at t ached to t he int ake s ide of t he cylinder head with 3 bolt s . Six fuel inject ors are inst alled in the cylinder headand connect ed to t he fuel rail. 'O' ring s eals are used t o seal t he inject ors in both t he fuel rail and cylinder head. A connection forthe fuel pres sure pipe is locat ed bet ween injectors 1 and 2.
There is a fuel rail press ure and t emperature s ens or located at t he end of t he fuel rail, next t o injector number 6. The press uresens or cont inuous ly monitors t he fuel pres s ure in the fuel rail, t his value is us ed by the ECM t o calculat e t he inject or puls e-widt hrequired to deliver the correct mas s of fuel per inject ion. The t emperat ure sensor meas ures t he t emperat ure of t he fuel in the fuelrail. This input is t hen us ed to deliver t he correct quant ity of fuel to the engine.For addit ional information, refer t o: Elect ronic Engine Cont rols (303-14A Elect ronic Engine Controls - I6 3.2L Pet rol, Des cript ion andOperation).
Vacuum Pump

ItemPart NumberDescription1-Vacuum pumpThe intake camshaft is equipped wit h t he VCT unit. The int ake cams haft also drives the vacuum pump.
• NOTE: W hen ins t alling the vacuum pump make sure t he s lot in the VCT unit and t he vacuum pump coupling are in t he vert icalposit ion t o aid ins t allat ion. The vert ical pos it ion is marked on the vacuum pump housing by 2 raised lines .
Intake Manifold
ItemPart NumberDescription1-Int ake manifold2-Variable plenum valve3-Bolt (7 of)4-Throt t le body and module

5-Bolt (2 of)6-Variable tract valveThe intake manifold att aches t o t he cylinder head wit h 6 bolt s and t he oil pan with 2 bolt s .
The manifold is capable of varying both int ake tract length and plenum volume by means of 2 separat e valves .
At low engine s peeds , long int ake tract s are ut iliz ed to provide opt imum engine t orque. Short er t racts are us ed at medium s peeds ,again, t o optimiz e engine t orque for t he exist ing engine s peed range.
At higher engine s peeds the benefit s of opt imizing t he t ract lengt hs are outweighed by the necess it y of maintaining anappropriate supply of air to meet t he engines requirement s . Therefore, t he plenum valve is opened t o create a s ingle, largeplenum volume to provide t he maximum quant ity of air t o charge the engines cylinders.For addit ional information, refer t o: Int ake Air Dis tribut ion and Filtering (303-12A Int ake Air Dis t ribution and Filt ering - I6 3.2LPet rol, Des cript ion and O perat ion).
Exhaust Manifold
ItemPart NumberDescription1-Exhaus t manifold as sembly2-Gas ket3-Exhaus t manifold - cylinders 1 t o 34-Exhaus t manifold - cylinders 4 t o 6The exhaus t manifold compris es 2 s eparat e manifold as semblies . One manifold is us ed for cylinders 1 t o 3 and t he secondmanifold is us ed for cylinders 4 t o 6. The manifolds are sealed t o the cylinder head wit h a gas ket and s ecured with 14 bolts .
Each manifold comprises 3 fabricat ed branches , which merge int o an int egral cat alyt ic convert er. A t hreaded bos s is posit ionedwhere t he 3 branches merge and provides for t he fit ment of a pre-catalyst Heat ed O xygen Sens or (HO2S). The cat alyt ic convert erout let s have offset flanges which mat e wit h corresponding flanges on t he front s ect ion exhaust s ys t em.
A bracket on each out let flange allows for t he at t achment of an exhaus t manifold heat shield.
CRANKSHAFT, BEDPLATE AND OIL PAN COMPONENTS
The crankshaft and oil pan components are:
Cranks haft and main bearingsCranks haft vibrat ion damper and cooling valveBedplat eO il filter and cooler ass emblyO il pump ass emblyO il pick-upO il panO il level gageSt art er mot or
Crankshaft and Main Bearings