LAND ROVER FRELANDER 2 2006 Repair Manual

Speci al Tool (s ):
310-163 Connect t he fuel li nes .
Inst all t he engi ne cover.
Refer t o: Engi ne Cover - TD4 2.2L Dies el (501-05 Interior Tri m and
Ornament ati on, Removal and Ins tal lat ion).
6.

Publi s hed: 11-May-2011
Fuel Tank and Lines - I6 3.2L Petrol -
C apacitiesItemCapacity (liters/gallons)
Fuel t ank70.0/15.4
General Specification
ItemSpecification
Syst em typeERFS Electronic Ret urnles s Fuel Sys temFuel del ivery modulePAG Modul e
Fuel pump:
Maximum output @ 11.5 volt s mi n110l/hr maxOperat ing press ureVariable
Maximum operati ng pres s ure3.8 Bar max
Fuel t ank s ender unit sMagneti c Pass ive Pos it ion Sens or (MAPPS)
Torque SpecificationsDescriptionNmlb-ft
Fuel t ank bolt s*2518
Fuel t ank fi ll er pi pe lower bracket107Fuel t ank fi ll er pi pe upper bracket107
* New nuts/bolts must be fitted

Publi s hed: 11-May-2011
Fuel Tank and Lines - I6 3.2L Petrol - Fuel Tank and Lines
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription1-Fil ler neck
2-Fuel tank
3-Evaporati ve emis s ion canis ter - Res t of W orld (ROW ) derivati ve4-Evaporati ve emis s ion canis ter - North Ameri can Specifi cat ion (NAS) deri vat ive

5-Vapor pipe t o evaporat ive emis s ion cani s ter
6-Vapor purge pipe t o i ntake manifold
7-Fuel del ivery pi pe to engi ne8-Breat her pi pe
ItemPart NumberDescription1-Roll Over Valve (ROV)
2-Cros s over t ube as sembl y
3-Fil l li mit vent val ve4-Coars e fuel fil ter
5-Fuel gage s ender uni ts
6-Primary fuel fi lt er7-Fuel del ivery modul e
8-Fuel fil ter el ement
OVERVIEW
The 70 l it er s addle-t ype fuel t ank is l ocat ed bel ow t he rear s eat and as t ri de the drives haft.
The fuel t ank is manufact ured us ing t he lat est s i x-layer lami nat ed blow-moldi ng technol ogy providing bot h high mechanicals trengt h and complet e emis s ions i ntegri ty. The fuel fill er neck i s produced from aluminum t o balance high-st rength wit hlow-weight. In t he event of an accident damagi ng the fil ler neck, an i nlet check valve i n t he tank's fil ler s tub prevent s fueles caping.
A s i ngl e pump s uppl ies t he engine's fuel demands whil e als o s upplying t he fuel t o power the vent uri. The rapi d flow of fuelt hrough the venturi nozzle creat es a depres s ion whi ch draws fuel back across the s addle i nto the pump si de of the tank.
The fuel gage s enders are s ealed unit s whi ch us e magnet ic actuat ion i n place of electrical contact s; t his prevent s the

problem of chemi cal contami nat ion of el ect ri cal components .
To meet on-board refuel ing vapor recovery (ORVR) requi rements , t he fuel t ank and as soci ated component s are des i gned t omi ni mi ze fuel vapor los s duri ng refuel ing. This i s achi eved by prevent ing fuel vapor from t he fuel t ank vent ing direct ly tot he atmos phere. Ins t ead fuel vapor is di rected into the evaporati ve emis s ion (EVAP) canis t er where i t is s t ored beforebeing purged at i ntervals to the engine’s intake mani fold.For addit ional informat ion, refer t o: Evaporat ive Emi s si ons (303-13 Evaporat ive Emi ss ions , Descripti on and Operat ion).
Roll Over Valve (ROV)
The ROV i s connected vi a pipes t o a l iquid vapour separat or. The s eparator i s connected via a pipe to t he t ank breatheroutl et in t he pump module fl ange. The ROV contai ns a non-ret urn val ve, whi ch cl oses i n t he event of t he vehi cl eoverturning, prevent ing l iquid fuel escaping from the tank via the breat her pi pe.

Publi shed: 13-Jul-2011
Fuel Tank and Lines - I6 3.2L Petrol - Fuel Tank and Lines
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the fuel tank and l ines s ys t ems , refer t o t he rel evant Des cript ion and Operat ion s ecti on in theworks hop manual .REFER to: Fuel Tank and Lines (310-01A Fuel Tank and Lines - I6 3.2L Pet rol , Descri pti on 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.
• NOTE: For di agnos t ic purpos es the cyli nders are divided i nt o t wo banks: Bank 1 - Cyl inder numbers 1, 2 and 3. Bank 2 -Cylinders 4, 5 and 6
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 Inspection
MechanicalElectricalFuel l eaksDamaged fuel l inesDamaged push connect fit t ingsFuel l evelFuel contami nati on/grade/quali tyDamaged fuel t ank fi ller pipe capDamaged fuel t ank fi ller pipe
FusesLoos e or corroded elect rical connect orsHarnes s esFuel Pump Dri ver Module (FPDM)Central Junct ion Box (CJB)Fuel pump relayEngine Control Modul e (ECM)
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, al ternat ively, check forDi agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
Symptom Chart
SymptomPossible CauseAction
Engine cranks , but does not fi reEngine breat her sys temdi sconnect ed/res trict edIgnit ion s yst emFuel sys temEl ect ronic engine controls
Ens ure t he engi ne breat her s ys tem is free fromres t ri ct ion and is correct ly i nst all edFor ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).For fuel s ys t em t est s . Read DTCs and refer t oDTC Index in t his secti onFor elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).
Engine cranks and fires , but wil lnot s tartEvaporati ve emis s ionspurge val veFuel pumpSpark pl ugsIgnit ion coil fai lure(s )
For purge valve t est s .REFER to: Evaporati ve Emis s ions (303-13Evaporati ve Emis s ions, Di agnos is and Tes t ing).For fuel pump t es t s . Check for DTCs and refert o DTC Index in t his s ecti onFor ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).
Di fficul t col d s t artCheck engi ne cool antl evel /anti -freeze cont entBat teryEl ect ronic engine controlsFuel pumpEvaporati ve emis s ionspurge val ve
Check the engine coolant level and condit ion.REFER to: Specifi cat ions (303-03A EngineCooli ng - I6 3.2L Petrol, Speci fi cat ions ).Ens ure t he batt ery i s in a ful ly charged ands erviceable condi ti onFor elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For fuel s ys t em t est s . Read DTCs and refer t oDTC Index in t his secti onFor purge valve t est s .REFER to: Evaporati ve Emis s ions (303-13Evaporati ve Emis s ions, Di agnos is and Tes t ing).

SymptomPossible CauseAction
Di fficul t hot st artInjector l eakEl ect ronic engine controlsEvaporati ve emis s ionspurge val veFuel pumpIgnit ion s yst emInjector l eak
Carry out inject or leak tes t s, i nst all newi nject ors as neces sary.REFER to: Fuel Inject or (303-04A Fuel Chargingand Controls - I6 3.2L Pet rol , Removal andInst all at ion).For elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For purge valve t est s .REFER to: Evaporati ve Emis s ions (303-13Evaporati ve Emis s ions, Di agnos is and Tes t ing).For fuel s ys t em t est s . Read DTCs and refer t oDTC Index in t his secti onFor ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).
Di fficul t t o s tart aft er hot s oak(vehi cl e s tanding, engi ne off,aft er engi ne has reachedoperat ing t emperature)
El ect ronic engine controlsEvaporati ve emis s ionspurge val veFuel pumpIgnit ion s yst em
Carry out inject or leak tes t s, i nst all newi nject ors as neces sary.REFER to: Fuel Inject or (303-04A Fuel Chargingand Controls - I6 3.2L Pet rol , Removal andInst all at ion).For elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For purge valve t est s .REFER to: Evaporati ve Emis s ions (303-13Evaporati ve Emis s ions, Di agnos is and Tes t ing).For fuel s ys t em t est s . Read DTCs and refer t oDTC Index in t his secti onFor ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).
Engine s t al ls s oon after s tartBreat her sys temdi sconnect ed/res trict edECM relayEl ect ronic engine controlsIgnit ion s yst emAi r intake s ys temrest ri ctedAi r leakageFuel lines
Ens ure t he engi ne breat her s ys tem is free fromres t ri ct ion and is correct ly i nst all edFor ECM rel ay and electroni c engi ne cont rol st est s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).Check for blockage i n air cl eaner element andair i ntake s yst emCheck for leakage in ai r int ake sys temFor fuel li ne tes t s. GO to Pinpoint Test A.
Engine hes it at es /pooraccel erati onFuel pres sure, fuel pump,fuel l inesInjector l eakAi r leakageEl ect ronic engine controlsIgnit ion s yst emTrans mi ss i on malfunct ionRes trict ed pedal t ravel(carpet, et c)
For fuel pres sure t est s . GO t o Pinpoint Tes t B.For fuel li ne tes t s. GO to Pinpoint Test A. Forfuel pump t es ts , check DTCs and refer to DTCIndex i n t his s ecti onCarry out fuel inject or leak t es t s, i nst all newi nject ors as neces sary.REFER to: Fuel Inject or (303-04A Fuel Chargingand Controls - I6 3.2L Pet rol , Removal andInst all at ion).Check for leakage from ai r intake s ys temFor elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).For trans mi s si on s ys t em t es ts .REFER to: Di agnos ti cs (307-01 Aut omati cTrans mi ss ion/Transaxle, Di agnos is andTes ti ng).Ens ure accel erator pedal i s free from res t rict ion
Engine backfiresFuel pump, fuel l inesAi r leakageEl ect ronic engine controlsIgnit ion s yst emSt icking vari abl e cams haftt iming (VCT) hub
For fuel pump t es t s . Read DTCs and refer t oDTC Index in t his secti on. For fuel l ine t est s .GO to Pi npoi nt Tes t A.Check for leakage from ai r intake s ys temFor elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A Engine

1
2
1
2
3
SymptomPossible CauseAction
Igni ti on, Di agnos is and Tes t ing).For VCT s ys t em t est s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).
Engine s urgesFuel pump, fuel l inesEl ect ronic engine controlsIgnit ion s yst em
For fuel pump t es t s , read DTCs and refer toDTC Index in t his secti on. For fuel l ine t est s .GO to Pi npoi nt Tes t A.For elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).
Engine detonat es /knocksEl ect ronic engine controlsFuel pump, fuel l ines , fuelquali tyAi r leakageSt icking VCT hub
For elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For fuel pump t es t s , read DTCs and refer toDTC Index in t his secti on. For fuel l ine t est s .GO to Pi npoi nt Tes t A.Check for leakage from ai r intake s ys temFor VCT s ys t em t est s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).
DTC Index
• NOTE: If a module or component i s s uspect, and t he vehi cl e remains under t he Manufacturers warranty, refer to theW arranty Pol icy and Procedure manual (s ecti on B1.2), or det ermi ne if any pri or approval programme i s in operat ion, pri or tot he ins tal lati on of a new modul e/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 ext rainformat ion read by the manufact urer-approved diagnost ic s ys tem).
• NOTE: W hen performing el ect ri cal volt age or resi s tance tes t s, al ways us e a digit al mult imet er (DMM) accurate to threedeci mal places , and wi th an up-to-date cali brat ion cert ificate. W hen t es ti ng res is t ance, always take t he res i st ance of t heDMM leads int 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: 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 .
For a compl ete lis t of all di agnos ti c troubl e codes that coul d be l ogged on t his vehicle, pleas e refer to s ect ion 100-00.REFER to:
Diagnos t ic Troubl e Code (DTC) Index - I6 3.2L Petrol, DTC: Engi ne Control Module (ECM) (100-00 GeneralInformat ion, Descri pti on and Operat ion),Diagnos t ic Troubl e Code (DTC) Index - I6 3.2L Petrol, DTC: Engi ne Control Module (ECM) - From 10MY (100-00,Descri pti on and Operat ion).
PINPOINT TEST A : CHECK THE FU EL LINES
T ESTCONDIT IONSDET AILS/RESULT S/ACT IONS
A1: CHECK T HE FUEL LINES FOR REST RICT IONS
W ARNING: This procedure invol ves fuel handl ing. Be prepared for fuel s pi ll age at al l ti mes andal ways obs erve fuel handli ng precaut ions . Fai lure to fol low t hese ins truct ions may res ul t in pers onali njury.
Det ach the fuel li ne from t he fuel rai l and from t he fuel pump modul e.
Usi ng an air l ine gentl y blow through the l ine checking for blockages or res t ri ct ions .
Is a bl ockage or res t ri ct ion evident?YesCLEAR/REPAIR t he blocked or rest ri cted fuel l ine and t es t the s ys tem for normal operat ion.NoGO t o A2.
A2: CHECK T HE FUEL T ANK LINES FOR REST RICT IONSRemove the fuel pump modul e l ocking ring.REFER t o: Fuel Pump and Sender Uni t (310-01A Fuel Tank and Lines - I6 3.2L Pet rol, Removal andIns tal lati on).
Det ach the fuel li nes from t he fuel pump module.
Usi ng an air l ine gentl y blow through the t ank li nes checki ng for blockages or rest ri cti ons .

1
2
3
1
2
3
4
5
6
7
1
2
1
Is a bl ockage or res t ri ct ion evident?YesCLEAR/REPAIR t he blocked or rest ri cted fuel l ine and t es t the s ys tem for normal operat ion.NoCHECK for DTCs and s ymptoms indicati ng anot her caus e for t he problem.REFER t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol , Diagnos i sand Tes t ing).
PINPOINT TEST B : CHECK THE FU EL SYSTEM PRESSURE
T ESTCONDIT IONSDET AILS/RESULT S/ACT IONS
B1: CHECK T HE PUMP ACT IVIT YRemove the rear s eat cus hion.REFER t o: Rear Seat Cus hi on (501-10 Seat ing, Removal and Inst all ati on).
Set i gni ti on s tat us to ON, engi ne OFF.
Li s ten for pump nois e.
Can the fuel pump be heard runni ng?YesGO t o B2.NoCHECK for DTCs .REFER t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol , Diagnos i sand Tes t ing).
B2: CHECK T HE FUEL SYST EM PRESSURE
W ARNING: This procedure invol ves fuel handl ing. Be prepared for fuel s pi ll age at al l ti mes andal ways obs erve fuel handli ng precaut ions . Fai lure to fol low t hese ins truct ions may res ul t in pers onali njury.
Make sure t he vehi cl e is in Park and apply the parki ng brake.
Set i gni ti on s tat us to OFF
• NOTE: Pl ace sui table abs orbent mat erial around t he Schraeder valve t o abs orb any spil lage whenconnect ing t he gauge set .
Connect adapt er 310-162 and gauge as sembl y 310-116 t o t he fuel Schraeder valve. Remove theabs orbent mat erial and dis pos e of safely.Dis connect and pl ug t he vacuum hos e from the press ure regulat or.
Open the valve on the fuel press ure gauge and adapter 310-116/162.
Set i gni ti on s tat us to ON, engi ne OFF.
Record the fuel press ure reading.
Is t he fuel pres s ure 3.6 - 4.2 bar (52.2 - 60.9 l b/in²)?YesGO t o B3.NoCHECK for DTCs .REFER t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol , Diagnos i sand Tes t ing).B3: CHECK T HE FUEL SYST EM PRESSURE WIT H T HE ENGINE CRANKING
Appl y foot brake and pres s s tart but t on.
Record the fuel press ure reading when engine cranki ng.
Is t he fuel pres s ure 3.6 - 4.2 bar (52.2 - 60.9 l b/in²)?YesGO t o B4.NoCHECK for DTCs .REFER t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol , Diagnos i sand Tes t ing).B4: CHECK T HE FUEL SYST EM PRESSURE WIT H T HE ENGINE IDLING (WHERE PO SSIBLE)
W it h engine runni ng.
Is t he fuel pres s ure 3.6 - 4.2 bar (52.2 - 60.9 l b/in²)?YesCHECK for DTCs and s ymptoms indicati ng anot her caus e of the probl em.REFER t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol , Diagnos i sand Tes t ing).NoCHECK the fuel pump module power and ground circui ts .

Publi s hed: 11-May-2011
Fuel Tank and Lines - I6 3.2L Petrol - Fuel Filter Element
Removal and Inst all ati on
Special T ool(s) 310-123
Locki ng Ring, Fuel Tank
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
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.
2. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he fuel tank.
Refer t o: Fuel Tank (310-01A Fuel Tank and Li nes - I6 3.2L Petrol,
Removal and Ins tall ati on).
3. Remove t he fuel tank pad.
4. 5. CAUTION: Extreme cleanli nes s mus t be
exercis ed when handl ing t hese components .
Remove t he fuel pump module locki ng ri ng.
Speci al Tool (s ): 310-123 T orque:
200 Nm 5.